Escolar Documentos
Profissional Documentos
Cultura Documentos
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8W - 90 - 10 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 11
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8W - 90 - 12 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 13
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8W - 90 - 14 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 15
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8W - 90 - 16 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 17
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8W - 90 - 18 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 19
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8W - 90 - 20 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 21
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8W - 90 - 22 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 23
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8W - 90 - 24 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 25
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8W - 90 - 26 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 27
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8W - 90 - 28 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 29
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8W - 90 - 30 8W - 90 CONNECTOR LOCATIONS ZG
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 31
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8W - 90 - 32 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Fig. 25 Underhood Lamp
Fig. 26 License Plate Lamps
ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 33
DESCRIPTION AND OPERATION (Continued)
8W-95 SPLICE LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng the
general l ocati on of the spl i ces i n thi s vehi cl e. A spl i ce
i ndex i s provi ded. Use the wi ri ng di agrams i n each
secti on for spl i ce number i denti fi cati on. Refer to the
i ndex for proper spl i ce number.
SPLICE LOCATIONS
For spl i ces that are not shown i n the fi gures i n
thi s secti on a N/S i s pl aced i n the Fi g. col umn.
Splice
Number
Location Fig.
S100 Near Power Distribution Center 1
S101 Near Battery Temperature Sensor T/O 1
S102 Near Battery Temperature Sensor T/O 1
S103 Near Battery Temperature Sensor T/O 1
S104 Right Front Corner of Engine
Compartment
1
S105 Right Front Corner of Engine
Compartment
1
S106 Right Front Corner of Engine
Compartment
1
S107 Left Front Corner of Engine
Compartment
1
S108 Left Front Corner of Engine
Compartment
1
S109 Near EVAP/Purge Solenoid T/O 1
S116 Near Branch to Brake Warning Switch 1
S117 In Branch to Brake Warning Switch 1
S118 In Branch to Brake Warning Switch 1
S119 Left Rear of Engine Compartment 1
S120 Near T/O to Low Washer Fluid Level
Sensor
1
S121 Near T/O to Low Washer Fluid Level
Sensor
1
S122 Near Vehicle Speed Control Servo
T/O
1
S123 Near Vehicle Speed Control Servo
T/O
1
S124 Near Vehicle Speed Control Servo
T/O
1
S125 Near Controller, Antilock Brakes 6
S126 Near A/C High Pressure Switch T/O
(4.0L Engine)
1
S126 In Branch to Starter Motor (5.2L
Engine)
3
S127 Near Injector No. 3 T/O (4.0L Engine) 2
S128 Near Injector No. 5 T/O (4.0L Engine) 2
Splice
Number
Location Fig.
S128 Near T/Os for Injectors 6 and 8 (5.2L
Engine)
3
S128 Near T/Os for A/C Compressor 4
S129 Rear of Engine (4.0L Engine) 2
S129 Near Injector No. 3 T/O (5.2L Engine) 3
S129 Rear of Engine (Diesel Engine) N/S
S130 Rear of Engine (4.0L Engine) 2
S130 Near Crankshaft Position Sensor T/O
(5.2L Engine)
3
S130 Near Crankshaft Position Sensor T/O
(Diesel Engine)
4
S131 In Branch to Transmission (4.0L
Engine)
2
S131 Right Rear of Engine (5.2L Engine) 3
S132 Near Branch to Transmission (4.0L
Engine)
2
S132 Rear of Engine (5.2L Engine) 3
S133 In Branch to Oil Pressure Sensor and
Crankshaft Position Sensor (4.0L
Engine)
2
S133 Near Injector No. 5 T/O (5.2L Engine) 3
S134 Near Branch to Powertrain Control
Module (4.0L Engine)
2
S134 Rear of Engine (5.2L Engine) 3
S134 Near Crankshaft Position Sensor T/O
(Diesel Engine)
4
S135 Near Branch to PCM (4.0L Engine) 2
S135 Right Rear of Engine (5.2L Engine) 3
S136 Near Injector No. 7 T/O (5.2L Engine) 3
S136 Near Crankshaft Position Sensor T/O
(Diesel Engine)
4
S138 Near Crankshaft Position Sensor T/O
(Diesel Engine)
4
S140 Rear of Engine (Diesel Engine) 4
S141 Rear of Engine (Diesel Engine) 4
S142 Near T/Os for A/C Compressor 4
ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 1
Splice
Number
Location Fig.
S200 Near Headlamp Switch T/O 5
S201 Near Headlamp Switch T/O 5
S202 Near Stop Lamp Switch T/O 5
S203 Near Stop Lamp Switch T/O 5
S204 Near Branch to Instrument Cluster 5
S205 Near Branch to Instrument Cluster 5
S206 Near Branch to Rear Window
Defogger Switch
5
S207 Near Shift Interlock T/O 5
S208 Near Branch to Shift Interlock T/O 5
S209 Near Branch to Shift Interlock T/O 5
S210 Near Transfer Case Illumination Lamp
T/O
5
S211 Near Branch to Graphic Display
Module/Vehicle Information Center
5
S212 Near Passenger Airbag T/O 5
S214 Near Passenger Airbag T/O 5
S215 Near Passenger Airbag T/O 5
S216 Near Passenger Airbag T/O 5
S218 Near Passenger Airbag T/O 5
S219 Near Branch to Graphic Display
Module/Vehicle Information Center
5
S220 Near Passenger Airbag T/O 5
S221 On HVAC Harness 7
S222 On HVAC Harness 7
S223 On HVAC Harness 7
S224 On HVAC Harness 7
S225 On HVAC Harness 7
S226 On HVAC Harness 7
S300 Near Left Kick Panel 6
S301 Near Left Kick Panel 6
S302 Near Left Kick Panel 6
S303 Near Branch to Floor Console 8
S304 Near Branch to Floor Console 8
S305 Near Branch to Left Rear Door 8
S306 Near Branch to Left Rear Door 8
S307 Near Branch to Left Rear Door 8
S308 Near Branch to Power Amplifier 8
S309 In Branch to Power Amplifier 8
S310 Near Branch to Power Amplifier 8
S311 Left Rear Quarter Panel 8
S312 Left Rear Quarter Panel 8
Splice
Number
Location Fig.
S313 Left Rear Quarter Panel 8
S314 Top of Left Rear Quarter Panel 8
S315 Top of Left Rear Quarter Panel 8
S316 Near Right Side T/O for Liftgate 9
S317 In Branch to Power Amplifier 8
S318 In Branch to Power Amplifier 8
S319 Near Branch to Right Rear Door Ajar
Switch
9
S320 In Branch to Dome/Reading Lamp 9
S321 Between Day/Night Mirror T/O and
Right Vanity Mirror T/O
10
S322 Between Day/Night Mirror T/O and
Right Vanity Mirror T/O
10
S323 Near Day/Night Mirror T/O 10
S324 In Left Front Door, Between Power
Window Motor T/O and Power Mirror
T/O
11
S325 In Right Front Door, Near Power
Window Motor T/O
11
S326 In Right Front Door, Near Power
Window Motor T/O
11
S327 In Right Front Door, Near Power
Window Motor T/O
11
S328 In Liftgate, Near Rear Window
Defogger T/O
12
S329 In Liftgate, Near Rear Wiper Motor
T/O
12
S330 In Factory Trailer Tow Harness, Near
Body Harness Connector
8
S331 In Factory Trailer Tow Harness, Near
Trailer Receptacle Harness Connector
8
S332 In Liftgate, Near Left Body Connectors 12
S333 Near T/O to Right Power Seat 9
S334 In Branch to Dome Reading Lamp 10
S335 In Branch to Power Amplifier 8
S336 In Liftgate, Between Rear Wiper Motor
T/O and Liftgate Lock Motor T/O
12
S400 In Left Power Seat Harness, Near
Lumbar Motor T/O
N/S
S401 In Left Power Seat Harness, Near
Riser Motor Sensor T/O
N/S
S402 In Left Power Seat Harness, Between
Riser Motor Sensor T/O and Heated
Seat Module T/O
N/S
S403 In Left Power Seat Harness, Near
Seat Switch T/O
N/S
8W - 95 - 2 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Splice
Number
Location Fig.
S404 In Right Power Seat Harness, Near
Seat Motor T/Os
N/S
S405 In Right Power Seat Harness, Near
Seat Motor T/Os
N/S
S406 In Right Power Seat Harness, In
Branch to Seat Switch
N/S
S407 In Left Power Seat Harness, Near
Lumbar Motor T/O
N/S
S408 Near Left Front Turn Signal Bulb
Socket
N/S
S409 Near Left Front Turn Signal Bulb
Socket
N/S
S410 Near Left Front Park Lamp Bulb
Socket
N/S
S411 In Left Tail Lamp Harness, Between
Body Connector and Grommet
N/S
Splice
Number
Location Fig.
S412 In Left Tail Lamp Harness, Between
Body Connector and Grommet
N/S
S413 Near Right Front Turn Signal Bulb
Socket
N/S
S414 Near Right Front Turn Signal Bulb
Socket
N/S
S415 Near Right Front Park Lamp Bulb
Socket
N/S
S416 In Right Tail Lamp Harness, Between
Body Connector and Grommet
N/S
S417 In Right Tail Lamp Harness, Between
Body Connector and Grommet
N/S
S418 In License Plate Lamp Harness 12
S419 In License Lamp Harness 12
S421 Fuse Link at PDC N/S
ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 3
DESCRIPTION AND OPERATION (Continued)
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8W - 95 - 4 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 5
DESCRIPTION AND OPERATION (Continued)
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8W - 95 - 6 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 7
DESCRIPTION AND OPERATION (Continued)
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8W - 95 - 8 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Fig. 6 Body Splices
Fig. 7 HVAC Harness Splices
ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 9
DESCRIPTION AND OPERATION (Continued)
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8W - 95 - 10 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 11
DESCRIPTION AND OPERATION (Continued)
Fig. 10 Roof Wiring Splices
Fig. 11 Front Door Harness Splices
8W - 95 - 12 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 13
DESCRIPTION AND OPERATION (Continued)
WIRING DIAGRAMS
CONTENTS
page page
8W-01 GENERAL INFORMATION . . . . . . . 8W-01-1
8W-02 COMPONENT INDEX . . . . . . . . . . . 8W-02-1
8W-10 POWER DISTRIBUTION . . . . . . . . 8W-10-1
8W-12 JUNCTION BLOCK . . . . . . . . . . . . . 8W-12-1
8W-15 GROUND DISTRIBUTION . . . . . . . 8W-15-1
8W-20 CHARGING SYSTEM . . . . . . . . . . . 8W-20-1
8W-21 STARTING SYSTEM . . . . . . . . . . . 8W-21-1
8W-30 FUEL/IGNITION SYSTEMS . . . . . . 8W-30-1
8W-31 TRANSMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-1
8W-33 VEHICLE SPEED CONTROL . . . . . 8W-33-1
8W-35 ALL-WHEEL ANTI-LOCK
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-1
8W-39 VEHICLE THEFT SECURITY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-1
8W-40 INSTRUMENT CLUSTER . . . . . . . . 8W-40-1
8W-41 HORN/CIGAR LIGHTER . . . . . . . . . 8W-41-1
8W-42 AIR CONDITIONING/HEATER . . . . 8W-42-1
8W-43 AIRBAG SYSTEM . . . . . . . . . . . . . 8W-43-1
8W-44 INTERIOR LIGHTING . . . . . . . . . . . 8W-44-1
8W-45 BODY CONTROL MODULE . . . . . . 8W-45-1
8W-46 MESSAGE CENTER . . . . . . . . . . . . 8W-46-1
8W-47 AUDIO SYSTEM . . . . . . . . . . . . . . 8W-47-1
8W-48 REAR WINDOW DEFOGGER . . . . . 8W-48-1
8W-49 OVERHEAD CONSOLE . . . . . . . . . . 8W-49-1
8W-50 FRONT LIGHTING . . . . . . . . . . . . . 8W-50-1
8W-51 REAR LIGHTING . . . . . . . . . . . . . . 8W-51-1
8W-52 TURN SIGNALS . . . . . . . . . . . . . . . 8W-52-1
8W-53 WIPERS . . . . . . . . . . . . . . . . . . . . . 8W-53-1
8W-54 TRAILER TOW . . . . . . . . . . . . . . . . 8W-54-1
8W-60 POWER WINDOWS . . . . . . . . . . . . 8W-60-1
8W-61 POWER DOOR LOCKS . . . . . . . . . 8W-61-1
8W-62 POWER MIRRORS . . . . . . . . . . . . 8W-62-1
8W-63 POWER SEAT . . . . . . . . . . . . . . . . 8W-63-1
8W-64 POWER SUNROOF . . . . . . . . . . . . 8W-64-1
8W-65 SPEED PROPORTIONAL
STEERING . . . . . . . . . . . . . . . . . . . . . . . 8W-65-1
8W-70 SPLICE INFORMATION . . . . . . . . . 8W-70-1
8W-80 CONNECTOR PIN-OUTS . . . . . . . . 8W-80-1
8W-90 CONNECTOR LOCATIONS . . . . . . . 8W-90-1
8W-95 SPLICE LOCATIONS . . . . . . . . . . . 8W-95-1
ZG WIRING DIAGRAMS 8W - 1
8W-01 GENERAL INFORMATION
INDEX
page page
DESCRIPTION AND OPERATION
CIRCUIT IDENTIFICATION . . . . . . . . . . . . . . . . . 3
CONNECTOR/GROUND LOCATIONS . . . . . . . . . 1
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . 5
HOW TO USE THIS GROUP . . . . . . . . . . . . . . . . 1
NOTES, CAUTIONS, and WARNINGS . . . . . . . . . 1
SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . 1
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 1
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WIRE CODE IDENTIFICATION . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
INTERMITTENT AND POOR CONNECTIONS . . . 5
TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . 6
TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . 5
TROUBLESHOOTING WIRING PROBLEMS . . . . 6
SERVICE PROCEDURES
CONNECTOR AND TERMINAL REPLACEMENT . 9
CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 8
DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . 10
TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . 9
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . 7
TERMINAL/CONNECTOR REPAIRTHOMAS
AND BETTS CONNECTORS . . . . . . . . . . . . . . 8
WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION AND OPERATION
HOW TO USE THIS GROUP
The purpose of thi s group i s to show the el ectri cal
ci rcui ts i n a cl ear, si mpl e fashi on and to make trou-
bl eshooti ng easi er. Components that work together
are shown together. Al l el ectri cal components used i n
a speci fi c system are shown on one di agram. The feed
for a system i s shown at the top of the page. Al l
wi res, connectors, spl i ces, and components are shown
i n the fl ow of current to the bottom of the page. Wi r-
i ng whi ch i s not part of the ci rcui t represented i s ref-
erenced to another page/secti on, where the compl ete
ci rcui t i s shown. I n addi ti on, al l swi tches, compo-
nents, and modul es are shown i n the at rest posi-
tion with the doors closed and the key removed
from the ignition.
I f a component i s part of several di fferent ci rcui ts,
i t i s shown i n the di agram for each. For exampl e, the
headl amp swi tch i s the mai n part of the exteri or
l i ghti ng, but i t al so affects the i nteri or l i ghti ng and
the chi me warni ng system. It is important to real-
ize that no attempt is made on the diagrams to
represent components and wiring as they
appear on the vehicle. For example, a short
piece of wire is treated the same as a long one.
In addition, switches and other components are
shown as simply as possible, with regard to
function only.
SECTION IDENTIFICATION
Secti ons i n Group 8W are organi zed by sub-sys-
tems. The secti ons contai n ci rcui t operati on descri p-
ti ons, hel pful i nformati on, and system di agrams. The
i ntenti on i s to organi ze i nformati on by system, con-
si stentl y from year to year.
CONNECTOR/GROUND LOCATIONS
Secti on 8W-90 contai ns connector/ground l ocati on
i l l ustrati ons. The i l l ustrati ons contai n the connector
name (or number)/ground number and component
i denti fi cati on. Connector/ground l ocati on charts i n
Secti on 8W-90 reference the i l l ustrati on number for
components and connectors.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the Di a-
gram pages.
SPLICE LOCATIONS
Spl i ce Locati on charts i n Secti on 8W-70 show the
enti re spl i ce, and provi de references to other secti ons
the spl i ce serves.
Secti on 8W-95 contai ns i l l ustrati ons that show the
general l ocati on of the spl i ces i n each harness. The
i l l ustrati ons show the spl i ce by number, and provi de
a wri tten l ocati on.
NOTES, CAUTIONS, and WARNINGS
Throughout thi s group addi ti onal i mportant i nfor-
mati on i s presented i n three ways; Notes, Cauti ons,
and Warni ngs.
NOTES are used to hel p descri be how swi tches or
components operate to compl ete a parti cul ar ci rcui t.
They are al so used to i ndi cate di fferent condi ti ons
ZG 8W - 01 GENERAL INFORMATION 8W - 01 - 1
that may appear on the vehi cl e. For exampl e, an
up-to and after condi ti on.
CAUTIONS are used to i ndi cate i nformati on that
coul d prevent maki ng an error that may damage the
vehi cl e.
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
WIRE CODE IDENTIFICATION
Each wi re shown i n the di agrams contai ns a code
(Fi g. 1) whi ch i denti fi es the mai n ci rcui t, part of the
mai n ci rcui t, gauge of wi re, and col or. The col or i s
shown as a two l etter code whi ch can be i denti fi ed by
referri ng to the Wi re Col or Code Chart (Fi g. 2)
Fig. 1 Wire Code Identification
Fig. 2 Wire Color Code Chart
8W - 01 - 2 8W - 01 GENERAL INFORMATION ZG
DESCRIPTION AND OPERATION (Continued)
CIRCUIT IDENTIFICATION
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i ts functi on (Fi g. 3). To
i denti fy whi ch ci rcui t code appl i es to a system, refer
to the Ci rcui t I denti fi cati on Code Chart. Thi s chart
shows the mai n ci rcui ts onl y and does not show the
secondary codes that may appl y to some model s.
CONNECTORS
Connectors shown i n the di agrams are i denti fi ed
usi ng the i nternati onal standard arrows for mal e and
femal e termi nal s (Fi g. 4). A connector i denti fi er i s
pl aced next to the arrows to i ndi cate the connector
number (Fi g. 4).
For vi ewi ng connector pi n outs, wi th two termi nal s
or greater, refer to secti on 8W-80. Thi s secti on i den-
ti fi es i n-l i ne connectors by number, and component
connectors by name. I f a component has two or more
connectors they wi l l be i denti fi ed as C1, C2, C3...etc.
Thi s secti ons al so provi des termi nal numberi ng, ci r-
cui t i denti fi cati on, wi re col ors, and functi ons.
Al l connectors are vi ewed from the termi nal end
unl ess otherwi se speci fi ed. To fi nd the connector l oca-
ti on i n the vehi cl e refer to secti on 8W-90. Thi s sec-
ti on uses the connector i denti fi cati on number from
the wi ri ng di agrams to provi de a fi gure number ref-
erence.
TAKE OUTS
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component.
SYMBOLS
Vari ous symbol s are used throughout the Wi ri ng
Di agrams. These symbol s can be i denti fi ed by refer-
ri ng to the symbol i denti fi cati on chart (Fi g. 5).
Fig. 3 Circuit Identification
Fig. 4 Connector Identification
ZG 8W - 01 GENERAL INFORMATION 8W - 01 - 3
DESCRIPTION AND OPERATION (Continued)
Fig. 5 Symbol Identification
8W - 01 - 4 8W - 01 GENERAL INFORMATION ZG
DESCRIPTION AND OPERATION (Continued)
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 6) i s used to i ndi cate thi s. When han-
dl i ng any component wi th thi s symbol compl y wi th
the fol l owi ng procedures to reduce the possi bi l i ty of
el ectrostati c charge bui l d up on the body and i nad-
vertent di scharge i nto the component. I f i t i s not
known whether the part i s ESD sensi ti ve, assume
that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part from i ts protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i ts package,
ground the package to a known good ground on the
vehi cl e.
DIAGNOSIS AND TESTING
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in todays vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-me-
gohm or greater impedance.
Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: - Most of the electrical components used
in todays vehicle are Solid State. When checking
resistance in these circuits use a meter with a
10-megohm or greater impedance. In addition, make
sure the power is disconnected from the circuit.
Circuits that are powered up by the vehicle electri-
cal system can cause damage to the equipment and
provide false readings.
Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 7). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y check the fol l owi ng i tems.
Connectors are ful l y seated
Spread termi nal s, or termi nal push out
Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i n
posi ti on
Di rt or corrosi on on the termi nal s. Any amount
of corrosi on or di rt coul d cause an i ntermi ttent prob-
l em
Damaged connector/component casi ng exposi ng
the i tem to di rt and moi sture
Wi re i nsul ati on that has rubbed through causi ng
a short to ground
Wi ri ng broke i nsi de of the i nsul ati on
Fig. 6 Electrostatic Discharge Symbol
Fig. 7 Probing Tool
ZG 8W - 01 GENERAL INFORMATION 8W - 01 - 5
DESCRIPTION AND OPERATION (Continued)
TROUBLESHOOTING TESTS
Before begi nni ng any tests on a vehi cl es el ectri cal
system use the Wi ri ng Di agrams and study the ci r-
cui t. Al so refer to the Troubl eshooti ng Wi ri ng Prob-
l ems secti on i n thi s secti on.
TESTING FOR VOLTAGE
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 8).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
TESTING FOR CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 9).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the fused ci rcui t.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng the i tems i n the fuse ci rcui t
one at a ti me. When the fuse bl ows the ci rcui t wi th
the short to ground has been i sol ated.
TESTING FOR A VOLTAGE DROP
(1) Connect the posi ti ve l ead of the vol tmeter to
the si de of the ci rcui t cl osest to the battery (Fi g. 10).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch or component.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
Fig. 8 Testing for Voltage
Fig. 9 Testing for Continuity
8W - 01 - 6 8W - 01 GENERAL INFORMATION ZG
DIAGNOSIS AND TESTING (Continued)
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em.
(6) Veri fy proper operati on. For thi s step check for
proper operati on of al l i tems on the repai red ci rcui t.
Refer to the wi ri ng di agrams.
SERVICE PROCEDURES
WIRING REPAIR
When repl aci ng or repai ri ng a wi re, i t i s i mportant
that the correct gauge be used as shown i n the wi r-
i ng di agrams. The wi res must al so be hel d securel y
i n pl ace to prevent damage to the i nsul ati on.
(1) Di sconnect battery negati ve cabl e
(2) Remove 1 i nch of i nsul ati on from each end of
the wi re.
(3) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Make sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(4) Spread the strands of the wi re apart on each
part of the exposed wi re (exampl e 1). (Fi g. 11)
(5) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on (exampl e
2) (Fi g. 11)
(6) Twi st the wi res together (exampl e 3) (Fi g. 11)
(7) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(8) Center the heat shri nk tubi ng over the joi nt,
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng.
(9) Secure the wi re to the exi sti ng ones to prevent
chafi ng or damage to the i nsul ati on
(10) Connect battery and test al l affected systems.
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Di sconnect battery.
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) I nsert the termi nal rel easi ng speci al tool 6742
i nto the termi nal end of the connector (Fi g. 12).
Fig. 10 Testing for Voltage Drop
Fig. 11 Wire Repair
Fig. 12 Molex Connector Repair
ZG 8W - 01 GENERAL INFORMATION 8W - 01 - 7
DIAGNOSIS AND TESTING (Continued)
(4) Usi ng speci al tool 6742 rel ease the l ocki ng fi n-
gers on the termi nal (Fi g. 13).
(5) Pul l on the wi re to remove i t from the connec-
tor.
(6) Repai r or repl ace the connector or termi nal , as
necessary.
TERMINAL/CONNECTOR REPAIR THOMAS AND
BETTS CONNECTORS
(1) Di sconnect battery.
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) Push i n the two l ock tabs on the si de of the
connector (Fi g. 14).
(4) I nsert the probe end of speci al tool 6934 i nto
the back of the connector cavi ty (Fi g. 15).
(5) Grasp the wi re and tool 6934 and sl owl y
remove the wi re and termi nal from the connector.
(6) Repai r or repl ace the termi nal .
(7) I nstal l the wi re and termi nal i n the connector.
Ful l y seat the termi nal i n the connector.
(8) Push i n the si ngl e l ock tab on the si de of the
connector (Fi g. 16).
CONNECTOR REPLACEMENT
(1) Di sconnect battery.
(2) Di sconnect the connector that i s to be repai red
from i ts mati ng hal f/component
(3) Remove the connector l ocki ng wedge, i f
requi red (Fi g. 17)
Fig. 13 Using Special Tool 6742
Fig. 14 Thomas and Betts Connector Lock Release
Tabs
Fig. 15 Removing Wire Terminal
Fig. 16 Single Lock Tab
Fig. 17 Connector Locking Wedge
8W - 01 - 8 8W - 01 GENERAL INFORMATION ZG
SERVICE PROCEDURES (Continued)
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 18) (Fi g. 19).
(5) Reset the termi nal l ocki ng tang, i f i t has one.
(6) I nsert the removed wi re i n the same cavi ty on
the repai r connector.
(7) Repeat steps four through si x for each wi re i n
the connector, bei ng sure that al l wi res are i nserted
i nto the proper cavi ti es. For addi ti onal connector pi n-
out i denti fi cati on, refer to the wi ri ng di agrams.
(8) I nsert the connector l ocki ng wedge i nto the
repai red connector, i f requi red.
(9) Connect connector to i ts mati ng hal f/compo-
nent.
(10) Connect battery and test al l affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Di sconnect battery.
(2) Di sconnect the connector (that i s to be
repai red) from i ts mati ng hal f/component.
(3) Cut off the exi sti ng wi re connector di rectl y
behi nd the i nsul ator. Remove si x i nches of tape from
the harness.
(4) Stagger cut al l wi res on the harness si de at
1/2 i nch i nterval s (Fi g. 20).
(5) Remove 1 i nch of i nsul ati on from each wi re on
the harness si de.
(6) Stagger cut the matchi ng wi res on the repai r
connector assembl y i n the opposi te order as was done
on the harness si de of the repai r. Al l ow extra l ength
for sol dered connecti ons. Check that the overal l
l ength i s the same as the ori gi nal (Fi g. 20).
(7) Remove 1 i nch of i nsul ati on from each wi re.
(8) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Be sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(9) Spread the strands of the wi re apart on each
part of the exposed wi res.
(10) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on.
(11) Twi st the wi res together.
(12) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(13) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng
(14) Repeat steps 8 through 13 for each wi re.
(15) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(16) Re-connect the repai red connector.
(17) Connect the battery, and test al l affected sys-
tems.
TERMINAL REPLACEMENT
(1) Di sconnect battery.
(2) Di sconnect the connector bei ng repai red from
i ts mati ng hal f. Remove connector l ocki ng wedge, i f
requi red (Fi g. 21).
Fig. 18 Terminal Removal
Fig. 19 Terminal Removal Using Special Tool
Fig. 20 Stagger Cutting Wires
ZG 8W - 01 GENERAL INFORMATION 8W - 01 - 9
SERVICE PROCEDURES (Continued)
(3) Remove connector l ocki ng wedge, i f requi red
(Fi g. 21).
(4) Posi ti on the connector l ocki ng fi nger away
from the termi nal usi ng the proper pi ck from speci al
tool ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 22) (Fi g. 23).
(5) Cut the wi re 6 i nches from the back of the
connector.
(6) Remove 1 i nch of i nsul ati on from the wi re on
the harness si de.
(7) Sel ect a wi re from the termi nal repai r assem-
bl y that best matches the col or wi re bei ng repai red.
(8) Cut the repai r wi re to the proper l ength and
remove 1 i nch of i nsul ati on.
(9) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Make sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(10) Spread the strands of the wi re apart on each
part of the exposed wi res.
(11) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on.
(12) Twi st the wi res together.
(13) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(14) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng.
(15) I nsert the repai red wi re i nto the connector.
(16) I nstal l the connector l ocki ng wedge, i f
requi red, and reconnect the connector to i ts mati ng
hal f/component.
(17) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(18) Connect battery, and test al l affected systems.
DIODE REPLACEMENT
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 24).
Fig. 21 Connector Locking Wedge Tab (Typical)
Fig. 22 Terminal Removal
Fig. 23 Terminal Removal Using Special Tool
Fig. 24 Diode Identification
8W - 01 - 10 8W - 01 GENERAL INFORMATION ZG
SERVICE PROCEDURES (Continued)
(4) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(5) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary refer to the
appropri ate wi ri ng di agram for current fl ow.
(6) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(7) Tape the di ode to the harness usi ng el ectri cal
tape maki ng, sure the di ode i s compl etel y seal ed
from the el ements.
(8) Re-connect the battery, and test affected sys-
tems.
SPECIAL TOOLS
WIRING/TERMINAL
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
ZG 8W - 01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)
8W-02 COMPONENT INDEX
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . 8W-42
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . 8W-42
A/C Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . . . 8W-42
A/C Low Pressure Swi tch . . . . . . . . . . . . . . . . 8W-42
ABS Warni ng Lamp . . . . . . . . . . . . . . . . . . . . 8W-40
Aftermarket Trai l er Tow Connector . . . . . . . . 8W-54
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . 8W-43
Ai rbag Warni ng Lamp . . . . . . . . . . . . . . . 8W-40, 43
Ambi ent Temperature Sensor . . . . . . . . . . 8W-42, 45
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . . 8W-44
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . 8W-44
Automati c Headl amp Li ght
Sensor/Vtss Led . . . . . . . . . . . . . . . . . . 8W-45, 50
Automati c Headl amp Rel ay . . . . . . . . . . . 8W-12, 50
Automati c Shut Down Rel ay . . . . . 8W-10, 20, 30, 42
Automati c Temperature Control Modul e . . . . 8W-42
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-51
Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15, 20
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . . 8W-42
Bl ower Power Modul e . . . . . . . . . . . . . . . . . . 8W-42
Body Control Modul e . . . . . . . . . . . . . 8W-39, 40, 45
Brake Warni ng Lamp . . . . . . . . . . . . . . . . . . . 8W-40
Brake Warni ng Swi tch . . . . . . . . . . . . . . . . . . 8W-40
Camshaft Posi ti on (CMP) Sensor . . . . . . . . . . 8W-30
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Center Hi gh Mounted Stop Lamps (CHMSL) . 8W-51
Check Engi ne Lamp . . . . . . . . . . . . . . . . . . . . 8W-40
Check Gages Lamp . . . . . . . . . . . . . . . . . . . . 8W-40
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Ci gar Li ghter Lamp . . . . . . . . . . . . . . . . . . . . 8W-44
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . 8W-41
Ci rcui t Breakers . . . . . . . . . . . . . . 8W-10, 12, 50, 54
Cl ockspri ng . . . . . . . . . . . . . . . . . . 8W-30, 33, 39, 47
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . . . 8W-21
Control l er Anti -Lock Brake . . . . . . . . . . . . . . 8W-35
Cool ant Level Sensor . . . . . . . . . . . . . . . . . . . 8W-30
Courtesy Lamp Rel ay . . . . . . . . . . . . . . . . . . . 8W-44
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Component Page
Crankshaft Posi ti on (CKP) Sensor . . . . . . . . . 8W-30
Crui se Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Cyl i nder Lock Swi tches . . . . . . . . . . . . . . . . . 8W-39
Data Li nk Connector . . . . . . . . . . . . . . . . . . . 8W-30
Dayti me Runni ng Lamp (DRL) Modul e . . . . . 8W-50
Dome/Readi ng Lamp . . . . . . . . . . . . . . . . . . . 8W-44
Door Ajar Swi tches . . . . . . . . . . . . . . . 8W-39, 44, 45
Door Courtesy Lamps . . . . . . . . . . . . . . . . . . . 8W-44
Door Lock Motors . . . . . . . . . . . . . . . . . . . . . . 8W-61
Door Speakers . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Dri ver Door Modul e . . . . . . . . . . . 8W-60, 61, 62, 63
Dri ver Heated Seat Back . . . . . . . . . . . . . . . . 8W-63
Dri ver Heated Seat Cushi on . . . . . . . . . . . . . 8W-63
Dri ver Lumbar Motor . . . . . . . . . . . . . . . . . . . 8W-63
Dri ver Lumbar Sensor/Motor . . . . . . . . . . . . . 8W-63
Dri ver Lumbar Swi tch . . . . . . . . . . . . . . . . . . 8W-63
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . . 8W-62
Dri ver Power Seat Front Ri ser Motor . . . . . . 8W-63
Dri ver Power Seat Front Ri ser Motor Sensor . 8W-63
Dri ver Power Seat Hori zontal Motor . . . . . . . 8W-63
Dri ver Power Seat Hori zontal Motor Sensor . 8W-63
Dri ver Power Seat Rear Ri ser Motor . . . . . . . 8W-63
Dri ver Power Seat Rear Ri ser Motor Sensor . 8W-63
Dri ver Power Seat Recl i ner Motor . . . . . . . . . 8W-63
Dri ver Power Seat Recl i ner Motor Sensor . . . 8W-63
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . . 8W-63
Dri ver Seat Heater Control Modul e . . . . . . . . 8W-63
Dri ver Si de Ai rbag . . . . . . . . . . . . . . . . . . . . . 8W-43
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . . 8W-30
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
El ectroni c Fl asher . . . . . . . . . . . . . . . . . . . . . 8W-52
Engi ne Cool ant Level Sensor . . . . . . . . . . . . . 8W-46
Engi ne Cool ant Temperature (ECT) Sensor . . 8W-30
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . 8W-21
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . 8W-21
Evaporati ve System Leak Detecti on Pump . . 8W-30
Factory Trai l er Tow Connector . . . . . . . . . . . . 8W-54
Fl oor Consol e Lamps . . . . . . . . . . . . . . . . . . . 8W-44
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12, 50
Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-50
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 51
Four Wheel Dri ve Swi tch . . . . . . . . . . . . . . . . 8W-46
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
ZG 8W - 02 COMPONENT INDEX 8W - 02 - 1
Component Page
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Sender Uni t . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuses (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
G Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Gl ow Pl ug . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Graphi c Di spl ay Modul e . . . . . . . . . . . . . . . . . 8W-46
Ground Di stri buti on . . . . . . . . . . . . . . . . . . . . 8W-15
Headl amp Di mmer Swi tch . . . . . . . . . . . . . . . 8W-50
Headl amp Level i ng Motors . . . . . . . . . . . . . . 8W-50
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . 8W-50
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-50
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Heated Oxygen Sensors . . . . . . . . . . . . . . . . . 8W-30
Heated Seat Swi tch . . . . . . . . . . . . . . . . . . . . 8W-63
Hi gh Beam I ndi cator Lamp . . . . . . . . . . . . . . 8W-40
Hi gh Speed Bl ower Motor Rel ay . . . . . . . . . . 8W-42
Hood Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-39, 41
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-39, 41
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39, 41
I dl e Ai r Control (I AC) Motor . . . . . . . . . . . . . 8W-30
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
I l l umi nati on Lamps . . . . . . . . . . . . . . . . . 8W-40, 44
I n-Car Temperature Sensor . . . . . . . . . . . . . . 8W-42
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-40
I nstrument Panel Speakers . . . . . . . . . . . . . . 8W-47
I ntake Ai r Temperature (I AT) Sensor . . . . . . . 8W-30
I ntermi ttent Wi per Rel ay . . . . . . . . . . . . . . . . 8W-53
I ntermi ttent Wi per Swi tch . . . . . . . . . . . . . . . 8W-53
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Key-I n Swi tch/Hal o Lamp . . . . . . . . . . . . 8W-44, 45
Lamp Outage Modul e . . . . . . . . . . . . . . . . . . . 8W-51
Li cense Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Li ftgate Ajar Swi tch . . . . . . . . . . . 8W-39, 44, 45, 53
Li ftgate Cyl i nder Lock Swi tch . . . . . . . . . . . . 8W-39
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . . . . 8W-61
Li ftgl ass Ajar Swi tch . . . . . . . . . . . . . 8W-39, 44, 45
Li ftgl ass Li mi t Swi tch . . . . . . . . . . . . . . . . . . 8W-61
Li ftgl ass Push Button . . . . . . . . . . . . . . . . . . 8W-61
Li ftgl ass Rel ease Sol enoi d . . . . . . . . . . . . . . . 8W-61
Low Fuel Warni ng Lamp . . . . . . . . . . . . . . . . 8W-40
Mani fol d Absol ute Pressure (MAP) Sensor . . . 8W-30
Mass Ai r Fl ow Modul e . . . . . . . . . . . . . . . . . . 8W-30
Memory Seat Modul e . . . . . . . . . . . . . . . . . . . 8W-63
Component Page
Memory Set Swi tch 1 Set . . . . . . . . . . . . . . . . 8W-63
Mercury Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Mode Door Actuator . . . . . . . . . . . . . . . . . . . . 8W-42
MSA Control l er . . . . . . . . . . . . . . . . . . 8W-10, 30, 33
Needl e Sensor . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Oi l Pressure Gauge . . . . . . . . . . . . . . . . . . . . 8W-40
Oi l Pressure Sensor . . . . . . . . . . . . . . . . . . . . 8W-30
Output Shaft Speed Sensor . . . . . . . . . . . 8W-30, 31
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . 8W-49
Park Brake Swi tch . . . . . . . . . . . . . . . . . . 8W-45, 50
Park Lamp Rel ay . . . . . . . . . . . . . 8W-12, 45, 50, 51
Park Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 52
Park/Neutral Posi ti on Swi tch . . . . . . . . . . 8W-30, 44
Passenger Door Modul e . . . . . . . . . . . 8W-60, 61, 62
Passenger Heated Seat Back . . . . . . . . . . . . . 8W-63
Passenger Heated Seat Cushi on . . . . . . . . . . . 8W-63
Passenger Lumbar Motor . . . . . . . . . . . . . . . . 8W-63
Passenger Lumbar Swi tch . . . . . . . . . . . . . . . 8W-63
Passenger Power Mi rror . . . . . . . . . . . . . . . . . 8W-62
Passenger Power Seat Front Ri ser Motor . . . . 8W-63
Passenger Power Seat Hori zontal Motor . . . . 8W-63
Passenger Power Seat Rear Ri ser Motor . . . . 8W-63
Passenger Power Seat Recl i ner Motor . . . . . . 8W-63
Passenger Power Seat Swi tch . . . . . . . . . . . . 8W-63
Passenger Seat Heater Control Modul e . . . . . 8W-63
Passenger Si de Ai rbag . . . . . . . . . . . . . . . . . . 8W-43
Pedal Posi ti on Sensor . . . . . . . . . . . . . . . . 8W-30, 31
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Power Antenna . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Power Antenna Rel ay . . . . . . . . . . . . . . . . 8W-12, 47
Power Di stri buti on Center . . . . . . . . . . . . . . . 8W-10
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Power Wi ndow Motors . . . . . . . . . . . . . . . . . . 8W-60
Power Wi ndow Swi tches . . . . . . . . . . . . . . . . . 8W-60
Powertrai n Control Modul e . . . . . . . . 8W-20, 30, 33
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Radi o Remote Swi tches . . . . . . . . . . . . . . . . . 8W-47
Rear Fog Lamp Rel ay A . . . . . . . . . . . . . . . . . 8W-51
Rear Speakers . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Rear Washer Pump Motor . . . . . . . . . . . . . . . 8W-53
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . 8W-48
Rear Wi ndow Defogger Rel ay . . . . . . . . . . 8W-12, 48
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . . 8W-48
Rear Wi per Modul e . . . . . . . . . . . . . . . . . . . . 8W-53
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8W-53
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . . . 8W-53
Reci rcul ati on Door Actuator . . . . . . . . . . . . . . 8W-42
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-45
Seat Bel t Warni ng Lamp . . . . . . . . . . . . . . . . 8W-40
Shi ft I nterl ock . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Si de Marker Lamps . . . . . . . . . . . . . . . . . . . . 8W-52
Si de Repeaters . . . . . . . . . . . . . . . . . . . . . . . . 8W-52
Sl i di ng Roof Motor . . . . . . . . . . . . . . . . . . . . . 8W-64
8W - 02 - 2 8W - 02 COMPONENT INDEX ZG
SPECIAL TOOLS (Continued)
Component Page
Sl i di ng Roof Posi ti on Swi tch . . . . . . . . . . . . . 8W-64
Sol ar Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Speed Proporti onal Steeri ng Control Modul e . 8W-65
Speed Proporti onal Steeri ng Modul e . . . . . . . 8W-65
Speed Proporti onal Steeri ng Sol enoi d . . . . . . 8W-65
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Spl i ce I nformati on . . . . . . . . . . . . . . . . . . . . . 8W-70
Steeri ng Wheel Speed Sensor . . . . . . . . . . . . . 8W-65
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-33
Sunroof Control Modul e . . . . . . . . . . . . . . . . . 8W-64
Sunroof Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-64
Swi tch Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Tai l /Stop Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Throttl e Posi ti on (TP) Sensor . . . . . . . . . . 8W-30, 31
Torque Converter Cl utch Sol enoi d . . . . . . . . . 8W-31
Trai l er Brake Provi si on . . . . . . . . . . . . . . . . . 8W-54
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . . . . 8W-54
Trai l er Tow Stop Lamp Rel ay . . . . . . . . . . . . . 8W-54
Trai l er Tow Turn Rel ays . . . . . . . . . . . . . . . . . 8W-54
Component Page
Transmi ssi on Control Rel ay . . . . . . . . . . . 8W-30, 31
Transmi ssi on Sol enoi d Assembl y . . . . . . . 8W-30, 31
Turn Si gnal I ndi cator Lamps . . . . . . . . . . . . . 8W-40
Turn Si gnal Lamps . . . . . . . . . . . . . . . 8W-40, 50, 52
Turn Si gnal /Hazard Warni ng Swi tch . . . . . . . 8W-52
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-44
Uni versal Garage Door Opener . . . . . . . . . . . 8W-44
Vari abl e Force Sol enoi d . . . . . . . . . . . . . . . . . 8W-31
Vehi cl e I nformati on Center . . . . . . . . . . . . . . 8W-46
Vehi cl e Speed Control Servo . . . . . . . . . . . . . . 8W-33
Vehi cl e Speed Control /Horn
Swi tch . . . . . . . . . . . . . . . . . 8W-30, 33, 39, 41, 47
Vehi cl e Speed Sensor . . . . . . . . . . . . . 8W-30, 31, 33
Vi sor/Vani ty Lamps . . . . . . . . . . . . . . . . . . . . 8W-44
Vol t Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . . 8W-30
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . 8W-35
Wi ndshi el d Washer Pump Motor . . . . . . . . . . 8W-53
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . . . . 8W-53
Wi per Fl ui d Level Sensor . . . . . . . . . . . . . 8W-46, 53
ZG 8W - 02 COMPONENT INDEX 8W - 02 - 3
SPECIAL TOOLS (Continued)
8W-02 COMPONENT INDEX
GENERAL INFORMATION
INTRODUCTION
Thi s secti on provi des an al phabeti cal l i sti ng of al l
the components covered i n group 8W. For i nformati on
on system operati on, refer to the appropri ate secti on
of the wi ri ng di agrams.
8W - 02 - 4 8W - 02 COMPONENT INDEX ZG
8W-10 POWER DISTRIBUTION
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . . 8W-10-4
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8W-10-4, 15
Automati c Headl amp Rel ay . . . . . . . . . . . . . . . 8W-10-11
Automati c Shut Down Rel ay . . . . . . . . . 8W-10-15, 16, 18
Automati c Temperature Control Modul e . . . . . . . 8W-10-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6
Bl ower Power Modul e . . . . . . . . . . . . . . . . . . . 8W-10-6
Body Control Modul e . . . . . . . . . . . . . . . . . . . 8W-10-15
Brake Warni ng Swi tch . . . . . . . . . . . . . . . . . . . 8W-10-7
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11
Ci rcui t Breaker 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9
Ci rcui t Breaker 2 . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Ci rcui t Breaker 3 . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . . . . 8W-10-7
Control l er Anti -Lock Brake . . . . . . . . . . . . . 8W-10-5, 10
Dayti me Runni ng Lamp Modul e . . . . . . . . . . . 8W-10-11
Downstream Heated Oxygen Sensor . . . . . . . . . 8W-10-17
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . . . 8W-10-15
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . . 8W-10-7
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . . 8W-10-7
Evaporati ve System Leak Detecti on Pump . . . . 8W-10-15
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . 8W-10-15, 18
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 3 . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 4 . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 5 . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 6 . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 7 . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel I njector No. 8 . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-10-14, 19
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . 8W-10-14, 15
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 4, 9
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 4, 9
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 8, 18
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 5, 8
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-5, 8
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 6, 10
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 7, 10
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 4, 9
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 8, 10
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8
Component Page
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 11, 12
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 9, 10
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 12
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 12, 13, 14
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 11, 14
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 13, 14
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 12, 13, 14
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . 8W-10-3, 12, 16, 18
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-4, 12
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-4, 19
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Headl amp Di mmer Swi tch . . . . . . . . . . . . . . . 8W-10-11
Headl amp Swi tch . . . . . . . . . . . . . . . . 8W-10-11, 13, 14
Hi gh Speed Bl ower Motor Rel ay . . . . . . . . . . . . 8W-10-6
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-5
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-5
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-5
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 8, 9
Juncti on Bl ock . . . . . . . . 8W-10-4, 8, 9, 10, 11, 12, 13, 14
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14
Mass Ai r Fl ow Modul e . . . . . . . . . . . . . . . . . . 8W-10-19
MSA Control l er . . . . . . . . . . . . . . . . . . 8W-10-15, 18, 19
Power Di stri buti on Center . 8W-10-3, 4, 5, 6, 7, 8, 9, 10, 11,
12, 13, 14, 16, 18
Powertrai n Control Modul e . . . . . . . 8W-10-13, 15, 16, 19
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . . 8W-10-4
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . . . 8W-10-4
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-5
S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 19
S129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 19
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-4
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7
S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6
S225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6
S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-4
Transmi ssi on Control Rel ay . . . . . . . . . . . . . . 8W-10-14
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . . . 8W-10-14
Upstream Heated Oxygen Sensor . . . . . . . . . . . 8W-10-17
ZG 8W - 10 POWER DISTRIBUTION 8W - 10 - 1
FUSE
1
175A
BATTERY GENERATOR
M2 M1
2 1 8
9 2
3
40A
40A
5
4 11
10 3 4
12 5
6
20A
40A
8
7 14
13 6
7
40A 20A
14
20 27
28 21
15
40A
30A
13
19 26
17 24
25 18
20A
10
16 23
22 15
9
20A
50A
11
12
FUSES
7
9 10 8
6
F19 20A
F20 20A
F21 15A F18 15A
F17 15A
F16 15A
18
17
20
19
22
21
11
12
14
13
16
15
2
5 3 4
1
16
19 18 20
17
11
13 15 14
12 2
4 5 3
1
7
10 8 9
6
6
9 8 10
7
1
3 5 4
2 12
14 15 13
11
17
20 18 19
16
13
12 14
11
10 2 8 5
9 6 3
1 4 7
D
C
B
A
ENGINE
STARTER
MOTOR
RELAY
WIPER RELAY
INTERMITTENT
ABS MAIN
RELAY
RELAY
CLUTCH
COMPRESSOR
A/C RELAY
SHUT DOWN
AUTOMATIC
HORN
RELAY
TRANSMISSION
CONTROL
RELAY
FUEL
PUMP
RELAY
POWER DISTRIBUTION CENTER
SEE PAGE 8W-10-20 FOR PDC PIN-OUT INFORMATION
8W - 10 - 2 8W-10 POWER DISTRIBUTION ZG-RHD
J978W-3 ZGR01001
A0
6
RD
S137
TO
175A
FUSE
1
POWER
DISTRIBUTION
CENTER
TO
JUNCTION
BLOCK
TO
40A
FUSE
3
50A
FUSE
5
40A
FUSE
7
TO
C160
40A
FUSE
8
TO
C233
20A
FUSE
10
TO
BLOCK
JUNCTION
20A
FUSE
14
FUEL
CONTROLLER
ANTI-LOCK
TO
A11
6
RD/BK OR/YL
12
A900
OR/YL
12
A900
RD/DB
10
A10
RD/VT
12
A19
RD/WT
12
A1
WT/OR
16
F61
RD/LG
14
A20 A250
10
RD
50A
FUSE
11
TO
BLOCK
JUNCTION
40A
FUSE
15
JUNCTION
BLOCK
TO
YL/RD
12
A7
20A
FUSE
16
A61
16
DG/BK
15A
FUSE
17
F92
18
LG
20A
FUSE
20
TO
S100
RD/YL
14
F5
CENTER
DISTRIBUTION
POWER
BATTERY
M2
M1
2
9
4
11
6
13
7
14
23
16
A13
A14
A20
A19
A11
A12
24
17
27
20
28
21
TO
BRAKE
ANTI-LOCK
CONTROLLER
TO
RELAY
PUMP
TO
CENTER
DISTRIBUTION
POWER
BRAKE
19
26
FUSE
30A
13
A6
14
RD/LB
JUNCTION
BLOCK
TO
A6
14
RD/LB
DAYTIME
RUNNING
LAMP
MODULE
TO
19
20A
A18
FUSE
A17
RD
BLOCK
JUNCTION
TO
18
F62
A12
RD/TN
12
3
30A
FUSE
10
4
CENTER
DISTRIBUTION
POWER
TO
(DIESEL)
TO
CENTER
DISTRIBUTION
POWER
RD/WT
A1
12
(GAS)
(GAS)
16
A11
15A
A12
FUSE
C131
TO
WT/RD
18
F6
(DIESEL)
A16
A15
18
FUSE
15A
F99
18
BR
S101
TO
(GAS)
A19
A20
(DIESEL)
20
FUSE
25A
F5
14
RD/YL
TO
AUTO
SHUT
DOWN
RELAY
(8W-10-16)
(8W-10-14)
(8W-10-13)
(8W-10-18)
(8W-10-13)
(8W-10-14)
(8W-10-11)
(8W-20-2)
(8W-20-3)
(8W-10-16)
(8W-10-14)
(8W-10-14)
(8W-10-12)
(8W-10-12)
(8W-10-10)
(8W-10-9)
(8W-10-7)
(8W-10-6)
(8W-10-5)
(8W-10-4)
(8W-10-4)
ZG-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 3
ZGR01002 J978W-3
M2
1
FUSE
175A
M1
BATT A0
A11
6
RD/BK
S137
A11
6
RD/BK
GENERATOR
2
3
FUSE
40A
9
A900
12
OR/YL
A22
21
FUSE
15A
A21
F250
18
RD/GY
B1
B2
(IN PDC)
RELAY
CLUTCH
COMPRESSOR
A/C
C2
18
DB/YL
1 C144
C2
18
DB/YL
C2
18
DB/YL
7 C131
C2
18
DB/YL
A/C
COMPRESSOR
CLUTCH
5.2L
A900
12
OR/YL
REAR
WINDOW
DEFOGGER
RELAY
JUNCTION
BLOCK
87
30 86
10A
FUSE
10
C15
12
BK/WT
1 C301
C15
12
BK/WT
2 C322
C15
12
BK/LB
S332
C15
12
BK
C15
12
BK/LB
DEFOGGER
WINDOW
REAR
LIFT-GLASS
C6
3
C2 3
OTHERS
DIESEL
AND 4.0L
CENTER
DISTRIBUTION
POWER
CENTER
DISTRIBUTION
POWER
85
(8W-10-3)
(8W-48-2)
(8W-12-9)
(8W-12-2)
(8W-48-2)
(8W-42-10)
(8W-42-11)
(8W-42-10)
(8W-42-11)
(8W-20-2)
(8W-20-3)
(8W-10-3)
(8W-10-3)
8W - 10 - 4 8W-10 POWER DISTRIBUTION ZG-RHD
J978W-3 ZGR01003
5
FUSE
50A
4
11
A10
10
RD/DB
25
CONTROLLER
ANTI-LOCK
BRAKE
BATT A0
5
12
6
FUSE
20A
RELAY
HORN
A2
A3 A1
FUSED
B(+)
X2
16
DG/YL
S106
X2
16
DG/YL
X2
16
DG/YL
1 1
NO. 1
HORN
NO. 2
HORN
CENTER
DISTRIBUTION
POWER
(8W-39-6)
(8W-41-2)
(8W-10-3)
(8W-39-6)
(8W-41-2)
(8W-39-6)
(8W-41-2)
(8W-35-2)
(8W-10-3)
ZG-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 5
ZGR01004 J978W-3
7
FUSE
40A
6
13
1 C160
A19
12
RD/VT
A19
12
RD
A19
10
RD
S225
A19
14
RD/VT
MANUAL
A/C
ATC
1
MOTOR
BLOWER
A19
12
DG/RD
2
5 1 3
BLOWER
POWER
MODULE
A19
10
RD
1
C42
12
BR/RD
C42
12
BR/RD
C42
12
RD
C42
12
BR/RD
M C206
C42
18
PK/DB
D2
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
S224
BATT A0
HIGH
SPEED
BLOWER
MOTOR
RELAY
OUTPUT
RELAY
MOTOR
BLOWER
SPEED
HIGH
M
CENTER
DISTRIBUTION
POWER
(8W-42-2)
(8W-42-3)
(8W-10-3)
(8W-42-3)
(8W-42-3)
(8W-42-3)
(8W-10-3)
8W - 10 - 6 8W-10 POWER DISTRIBUTION ZG-RHD
J978W-3 ZGR01005
8
FUSE
40A
7
14
C6
C7
ENGINE
STARTER
MOTOR
RELAY
CENTER
DISTRIBUTION
POWER
BATT A0
6 C144
T40
12
LG/BK
T40
12
LG/BK
2
ENGINE
STARTER
MOTOR
A1
12
RD/WT
E1 C233
A1
12
RD/WT
S210
IGNITION
SWITCH
1 START
2 RUN
0 OFF
3 ACC
3
0 2
1
7
2
4
1 6
A1
12
RD/WT
A1
12
RD/WT
A21
12
DB/GY
ST-RUN A21
A41
14
YL
E4 C233
C8
(IN PDC)
RELAY
MOTOR
STARTER
ENGINE
A141
14
YL/RD
A31
12
RD/BK
RUN-ACC A31
5
A22
12
BK/OR
RUN A22
3
0 2
1 3
0 2
1 1
2 0
3
3
G9
18
GY/BK
F5 C234
G9
16
GY/BK
BRAKE
WARNING
SWITCH
2
M
DIESEL GAS
1
SWITCH
INTERLOCK
CLUTCH
(8W-21-3)
(8W-10-3)
(8W-40-6)
(8W-10-8)
(8W-10-8)
(8W-10-9)
(8W-10-3)
(8W-21-3)
(8W-21-4)
(8W-21-3)
(8W-21-4)
(8W-21-3)
(8W-21-4)
ZG-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 7
ZGR01006 J978W-3
5 2
1
2 0
3
3 ACC
0 OFF
2 RUN
1 START
SWITCH
IGNITION
BATT A1 BATT A1
A21
12
DB/GY
2
5
FUSE
10A
JUNCTION
BLOCK
A16
18
FUSE
15A
A15
A21
12
DB/GY
4
FUSE
10A
JUNCTION
BLOCK
10A
FUSE
22
10A
FUSE
12
10A
FUSE
11
15A
FUSE
6
A22
12
BK/OR
10
C6
C2
1
C5
3
0 2
1
CENTER
DISTRIBUTION
POWER
(8W-10-13)
(8W-10-14)
(8W-10-7) (8W-10-7)
(8W-12-6) (8W-12-9) (8W-12-10) (8W-12-23)
(8W-12-2)
(8W-12-5)
(8W-12-2)
(8W-12-5)
(8W-10-3)
8W - 10 - 8 8W-10 POWER DISTRIBUTION ZG-RHD
J978W-3 ZGR01007
23
16
10
FUSE
20A
BATT A0
6
3 ACC
0 OFF
2 RUN
1 START
SWITCH
IGNITION
E2 C233
F61
16
WT/OR
F61
16
WT/OR
A31
12
RD/BK
4 C6
JUNCTION
BLOCK
14
FUSE
15A
10A
FUSE
1
15A
FUSE
2
10A
FUSE
3
20A
1
BREAKER
CIRCUIT
C6 1
BATT A1
3
0 2
1
10A
FUSE
15
30
87
REAR
FOG
LAMP
RELAY
CENTER
DISTRIBUTION
POWER
A
(8W-10-12)
(8W-10-7) (8W-10-3)
(8W-12-4)
(8W-12-4) (8W-12-3) (8W-12-3)
(8W-12-3)
(8W-12-2)
(8W-51-7)
(8W-10-3)
ZG-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 9
ZGR01008 J978W-3
17
24
11
FUSE
50A
A250
10
RD
C2 4
JUNCTION
BLOCK
30A
2
BREAKER
CIRCUIT
15A
FUSE
9
BATT A0
20A
FUSE
7
20A
FUSE
8
14
FUSE
20A
27
20
A20
14
RD/LG
9
CONTROLLER
ANTI-LOCK
BRAKE
FUSED
B(+)
CENTER
DISTRIBUTION
POWER
(8W-10-3)
(8W-35-2)
(8W-12-8) (8W-12-8) (8W-12-7)
(8W-12-7)
(8W-12-2)
(8W-10-3)
8W - 10 - 10 8W-10 POWER DISTRIBUTION ZG-RHD
J978W-3 ZGR01009
26
13
FUSE
30A
19
BATT A0
A6
14
RD/LB
C1 8
15A
FUSE
17
87
30 86
8
C5
F34
16
TN/BK
19
SWITCH)
FUNCTION
MULTI-
(PART OF
SWITCH
DIMMER
HEADLAMP
A6
14
RD/LB
11
9
25A
BREAKER
CIRCUIT
4 LOW
3 PARK
2 OFF
1 AUTO
SWITCH
HEADLAMP
JUNCTION
BLOCK
F34 16TN/BK
9
C5
AUTOMATIC
HEADLAMP
RELAY
4
3 2
1
CENTER
DISTRIBUTION
POWER
(8W-10-3)
(8W-50-2)
(8W-12-2)
(8W-50-5)
(8W-50-2)
(8W-12-14)
(8W-10-3)
ZG-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 11
ZGR01010 J978W-3
28
21
15
FUSE
40A
BATT A0
A7
12
YL/RD
C2 2
JUNCTION
BLOCK
15A
FUSE
13
16
FUSE
10A
15A
FUSE
19
20
FUSE
15A
15A
FUSE
21
20A
3
BREAKER
CIRCUIT
CENTER
DISTRIBUTION
POWER
(8W-10-3)
(8W-12-18)
(8W-12-16)
(8W-12-16)
(8W-12-16)
(8W-12-12)
(8W-12-11)
(8W-12-2)
(8W-10-3)
8W - 10 - 12 8W-10 POWER DISTRIBUTION ZG-RHD
J978W-3 ZGR01011
A11
A12
16
FUSE
15A
BATT A0
11 C131
F6
18
WT/RD
3
POWERTRAIN
CONTROL
MODULE
A16
A15
15A
FUSE
18
ST-RUN A21
F99
18
OR
TO
S101
A
(8W-10-15)
A18
RD
18
F62
A17
20A
FUSE
19
5
JUNCTION
BLOCK
C1
87
30 86
FOG
LAMP
RELAY
8 C7 4 C1
FOG
LAMP
LEFT
2 2
RIGHT
LAMP
FOG
4
HEADLAMP
SWITCH
20
LB
L39
18
LB
L39
L39
18
LB
L39
18
LB
S105
C4
WT/RD
18
F6
FUSED
B (+)
CENTER
DISTRIBUTION
POWER
(8W-12-24)
(8W-50-7)
(8W-50-6) (8W-50-6)
(8W-50-6)
(8W-12-2)
(8W-10-8) (8W-10-3)
(8W-30-22)
(8W-10-3)
ZG-RHD 8W-10 POWER DISTRIBUTION
DIESEL ENGINE
8W - 10 - 13
ZGR01012 J978W-3
F99
18
OR
C1 A2
F99
20
OR
2 C131
MODULE
CONTROL
POWERTRAIN
FUSED
IGN.
(ST-RUN)
B3
RELAY
CLUTCH
COMPRESSOR
A/C
F99
20
OR
F99
18
OR
C18
(IN PDC)
(IN PDC)
RELAY
PUMP
FUEL
OR
20
F99
OR
20
F99
B18
(ST-RUN)
IGN.
FUSED
C236 H8
OR
20
F99
18 C1
(IN PDC)
RELAY
DOWN
SHUT
AUTOMATIC
F99
20
OR
F99
20
OR
1
SOLENOID
PURGE
EVAP/
CYCLE
DUTY
2
PUMP
DETECTION
LEAK
SYSTEM
EVAPORATIVE
S101
A
(8W-10-13)
FROM
CENTER
DISTRIBUTION
POWER
F99
20
OR
MODULE
CONTROL
BODY
(GAS)
(GAS)
(GAS) (GAS)
(GAS)
MSA
CONTROLLER
38
(DIESEL)
F99
OR
20 18
OR
F99
S138
FUEL
RELAY
(DIESEL)
HEATER
D13
20
OR
F99
(8W-30-27)
(8W-30-22)
(8W-45-2)
(8W-30-4)
(8W-30-4)
(8W-30-5)
(8W-30-16)
(8W-42-10)
(8W-30-4)
(8W-30-22)
(8W-10-14)
ZG-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 15
ZGR01013 J978W-3
A19
20
FUSE
20A
A20
BATT A0
F5
14
RD/YL
F5
14
RD/YL
5 C131
F5
14
RD/YL
C1 A22
MODULE
CONTROL
POWERTRAIN
FUSED
B(+)
F5
18
RD/YL
B16
B17
(IN PDC)
RELAY
DOWN
SHUT
AUTOMATIC
C12 C3
AUTOMATIC
SHUT
DOWN
RELAY
OUTPUT
A142
18
DG/OR
A142
18
DG/OR
TO
C131
S100
B
(8W-10-17)
CENTER
DISTRIBUTION
POWER
(8W-10-3)
(8W-30-5)
(8W-30-4)
(8W-30-5)
(8W-10-3)
8W - 10 - 16 8W-10 POWER DISTRIBUTION
GAS ENGINES
ZG-RHD
J978W-3 ZGR01014
A142
18
DG/OR
4 C131
A142
18
DG/OR
A142
18
DG/OR
4.0L 5.2L 1
1
A142
18
DG/OR
A142
18
DG/OR DG/OR
18
A142
DG/OR
18
A142
1
1 1
1
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
1
1
A142
18
DG/OR
A142
18
DG/OR
IGNITION
COIL
(5.2L)
S128
1
1
A142
18
DG/OR
A142
18
DG/OR DG/OR
18
A142
DG/OR
18
A142
1
1
DG/OR
18
A142
1 1
A142
18
DG/OR DG/OR
18
A142
2
(4.0L)
COIL
IGNITION
SENSOR
OXYGEN
HEATED
UPSTREAM DOWNSTREAM
HEATED
OXYGEN
SENSOR
S129
B
(8W-10-16)
AUTOMATIC
SHUT
DOWN
RELAY
FROM
FUEL
INJECTOR
NO. 2 NO. 4
INJECTOR
FUEL FUEL
INJECTOR
NO. 6
(4.0L)
NO. 1
INJECTOR
FUEL
FUEL
INJECTOR
NO. 3
(4.0L) (4.0L)
NO. 5
INJECTOR
FUEL
FUEL
INJECTOR
NO. 1
(5.2L) (5.2L)
NO. 5
INJECTOR
FUEL
(5.2L)
NO. 7
INJECTOR
FUEL
(5.2L)
NO. 3
INJECTOR
FUEL
(5.2L)
NO. 8
INJECTOR
FUEL
(8W-30-12) (8W-30-11) (8W-30-11)
(8W-30-11) (8W-30-11)
(8W-30-15) (8W-30-15)
(8W-30-15)
(8W-30-15) (8W-30-15) (8W-30-15)
(8W-30-13)
(8W-30-14)
(8W-30-13)
(8W-30-14)
(8W-30-5)
(8W-30-5)
ZG-RHD 8W-10 POWER DISTRIBUTION
GAS ENGINES
8W - 10 - 17
ZGR01015 J978W-3
25A
FUSE
20
30A
FUSE
4
A12
12
RD/TN
BATT F61
D10
B18 B16
B17
C
(8W-10-19)
3
10 A19
A20
F5
16
RD/YL
B20
F5 16 RD/YL
42
AUTOMATIC
SHUTDOWN
RELAY
CONTROL
TO
S129
AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)
K900
20
PK/BK
K900
20
PK/BK
A142
16
DG/OR
A142
16
DG/OR
14 C132 12 C131
CONTROLLER
MSA
(IN PDC)
RELAY
HEATER
FUEL
CENTER
DISTRIBUTION
POWER
(8W-10-9)
(8W-30-27)
(8W-30-27)
(8W-10-3)
8W - 10 - 18 8W-10 POWER DISTRIBUTION
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR01017
FROM
C131
A142
16
DG/OR
S129
3
GLOW
PLUG
RELAY
57
MODULE
CONTROL
POWERTRAIN
AUTOMATIC
SHUTDOWN
RELAY
OUTPUT
1
SOLENOID
EGR
C4
A142
16
DG/OR
A142
16
DG/OR
A142
16
DG/OR
A142
16
DG/OR
S128
68
CONTROLLER
MSA
45 23
AUTOMATIC
SHUTDOWN
RELAY
OUTPUT OUTPUT
RELAY
SHUTDOWN
AUTOMATIC AUTOMATIC
SHUTDOWN
RELAY
OUTPUT
A142
16
DG/OR
A142
16
DG/OR
A142
14
DG/OR
OUTPUT
RELAY
SHUTDOWN
AUTOMATIC
OUTPUT
RELAY
SHUTDOWN
AUTOMATIC
9 10
FUEL
PUMP
MODULE
AUTOMATIC
SHUTDOWN
RELAY
OUTPUT
3
MODULE
FLOW
AIR
MASS
GENERATOR
1
A142
16
DG/OR
A142
14
DG/OR
A142
18
DG/OR
A142
16
DG/OR
C
(8W-10-18)
(8W-30-26) (8W-30-27)
(8W-30-28)
(8W-30-25)
(8W-30-26)
(8W-20-2)
ZG-RHD 8W-10 POWER DISTRIBUTION
DIESEL ENGINE
8W - 10 - 19
ZGR01018 J978W-3
FUSE NO. AMPS
1
A11 6RD/BK
-
A900 12OR/YL
2
3
A12 12RD/TN
4
A19 12RD/VT
5
6
A1 12RD/WT
7
A250 10RD
F61 16WT/OR
8
10
A6 14RD/LB
9
-
A6 14RD/LB
11
A20 14RD/LG
12
A7 12YL/RD
13
14
F99 18OR
15
F62 18RD
F5 14RD/YL
A61 16DG/BK
A7 12YL/RD
16
17
F92 18LG
B(+)
SPARE
FUSED B(+)
SPARE
8W-10-7
FUSED B(+)
SPARE
18
19
20
21
20
20
15
15
20
40
20
30
-
50
20
-
40
40
20
50
30
40
-
175
-
F31 16VT
A10 10RD/DB
A900 12OR/YL
A1 12RD/WT
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (ST/RUN)
15 F250 18RD/GY
FUSED B(+)
FEED CIRCUIT FUSED CIRCUIT
FUSED B(+)
*
-
-
-
17
FUSED B(+)
25 20
F5 14RD/YL
*
*
**
**
** GAS
* DIESEL
**
16 15
A61 18WT/RD FUSED B(+)
*
8W - 10 - 20 8W-10 POWER DISTRIBUTION ZG-RHD
J978W-3 ZGR01019
FUSED B(+)
X2 16DG/YL
A1
FUNCTION CIRCUIT CAV
A2
F31 16VT
HORN RELAY OUTPUT
FUSED B(+)
F31 16VT
A3
A4
A9
- -
RELAY
HORN
TRANSMISSION
CONTROL
RELAY
- -
A8
K72 18DG/VT VOLTAGE REGULATION
TRANSMISSION RELAY OUTPUT T20 18LB
A7
CAV CIRCUIT FUNCTION
A6
F92 18LG
FUSED B(+)
ABS WARNING LAMP RELAY OUTPUT F250 18RD/GY
B1
FUNCTION CIRCUIT CAV
B2
C2 18DB/YL AUTOMATIC SHUT DOWN RELAY OUTPUT
FUSED IGNITION SWITCH OUPUT (RUN) F99 20OR
B3
B4
- -
CLUTCH
COMPRESSOR
A/C
RELAY
A10
B120 12BR/WT ABS PUMP MOTOR RELAY OUTPUT
X4 20GY/OR
A5
HORN RELAYCONTROL
F31 16VT
FUSED B(+)
B5 C13 18DB/RD A/C COMPRESSOR CLUTCH RELAY CONTROL
ZG-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 21
ZGR01020 J978W-3
AUTOMATIC
SHUT DOWN
RELAY
B17
B16
F5 16RD/YL * FUSED IGNITION SWITCH OUTPUT (ST/RUN)
F5 16RD/YL *
B16
CAV CIRCUIT FUNCTION
B16
F5 18RD/YL FUSED B(+)
FUSED B(+)
FUSED B(+)
WIPER PARK SWITCH SENSE V6 16DB
FUNCTION CIRCUIT CAV
C1
F86 16LG/RD *
F86 18LG/RD **
C2
C3
F86 16LG/RD
RELAY
WIPER
INTERMITTENT
A142 18DG/OR
B17
FUSED B(+)
C5
C4
V66 18VT/WT
V18 20YL/LG
WIPER PARK SWITCH SENSE
INTERMITTENT WIPER RELAY CONTROL
FUSED B(+)
FUSED B(+)
AUTOMATIC SHUT DOWN RELAY CONTROL
B20
K900 20PK/WT
FUSED B(+)
FUSED B(+) A142 16DG/OR
B17
B18
F5 16RD/YL
FUSED IGNITION SWITCH OUTPUT (ST/RUN) F99 20OR
B18
B20
A142 18DG/OR FUSED B(+)
K900 20PK/WT AUTOMATIC SHUT DOWN RELAY CONTROL
* DIESEL
** GAS
8W - 10 - 22 8W-10 POWER DISTRIBUTION ZG-RHD
J978W-3 ZGR01021
- -
C9
C8
T141 14YL/RD FUSED IGNITION SWITCH OUTPUT (ST)
T40 12LG/BK
C7
CAV CIRCUIT FUNCTION
C6
A1 12RD/WT FUSED B(+)
ENGINE STARTER MOTOR RELAY OUTPUT
FUEL PUMP RELAY OUTPUT
FUSED B(+) A61 16DG/BK
FUNCTION CIRCUIT CAV
C16
A64 16DG/WT
F99 200R
C17
C18
-
RELAY
PUMP
FUEL
Z4 20BK
C10
PARK NEUTRAL POSITION SWITCH SENSE
C20
C19
K81 18DB
FUEL PUMP RELAY CONTROL
FUSED IGNITION SWITCH OUTPUT (ST/RUN)
-
ENGINE
STARTER
MOTOR
RELAY
PARK NEUTRAL POSITION SWITCH SENSE
C10
T41 20BK/WT
*
**
FUEL HEATER FEED
A64 14OR/DB
D13
D14
FUEL
HEATER
RELAY
F99 20OR
D12
D11
-
Z4 20BK
D10
CAV CIRCUIT FUNCTION
A12 12RD/TN FUSED B(+)
GROUND
(DIESEL)
FUSED IGNITION SWITCH OUTPUT (ST/RUN)
-
* GAS
** DIESEL
ZG-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 23
ZGR01022 J978W-3
8W-10 POWER DISTRIBUTION
DESCRIPTION AND OPERATION
Thi s secti on covers the power di stri buti on center
and al l ci rcui ts i nvol ved wi th i t. For addi ti onal i nfor-
mati on on system operati on, refer to the appropri ate
wi ri ng di agrams.
8W - 10 - 24 8W - 10 POWER DISTRIBUTION ZG
8W-12 J UNCTION BLOCK
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Component Page
A/C Heater Control . . . . . . . . . . . . . . . . . . . 8W-12-10
Aftermarket Trai l er Tow Connector . . . . . . . . 8W-12-8
Ai rbag Control Modul e . . . . . . . . . . . . . . . 8W-12-5, 23
Automati c Day/Ni ght Mi rror . . . . . . . . 8W-12-7, 17, 21
Automati c Headl amp Li ght Sensor/Vtss Led . . 8W-12-8
Automati c Headl amp Rel ay . . . . . . . . . . . . . 8W-12-24
Automati c Temperature Control Modul e . 8W-12-10, 16
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-12-6
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-12-10
Body Control Modul e . . . . . . . 8W-12-4, 8, 9, 14, 23, 24
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-12-12, 22
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-3
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12-3
Ci rcui t Breaker 1 . . . . . . . . . . . . . . . . . . . . . 8W-12-4
Ci rcui t Breaker 2 . . . . . . . . . . . . . . . . . . . . . 8W-12-7
Ci rcui t Breaker 3 . . . . . . . . . . . . . . . . . . . . . 8W-12-18
Control l er Anti -Lock Brake . . . . . . . . . . . . . . 8W-12-9
Courtesy Lamp Rel ay . . . . . . . . . . . . . . . 8W-12-12, 22
Data Li nk Connector . . . . . . . . . . . . . . . . . . . 8W-12-8
Dome/Readi ng Lamp . . . . . . . . . . . . . . . 8W-12-13, 21
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . . . 8W-12-7
Dri ver Lumbar Swi tch . . . . . . . . . . . . . . . . . 8W-12-18
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . 8W-12-18
Dri ver Seat Heater Control Modul e . . . . . 8W-12-10, 18
El ectroni c Fl asher . . . . . . . . . . . . . . . . . . 8W-12-6, 11
Factory Trai l er Tow Connector . . . . . . . . . . . 8W-12-17
Fog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Four Wheel Dri ve Swi tch . . . . . . . . . . . . . . . 8W-12-19
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-3
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-3
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-4
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-3
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . 8W-12-12
Graphi c Di spl ay Modul e . . . . . . . . 8W-12-6, 16, 19, 21
Headl amp Di mmer Swi tch . . . . . . . . . . . 8W-12-16, 24
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . 8W-12-6
Component Page
Headl amp Swi tch . . . . . . . . . . . . . . . 8W-12-14, 20, 24
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23
I nstrument Cl uster . . . . . . . . . . . . . . . 8W-12-5, 8, 17
I ntermi ttent Wi per Rel ay . . . . . . . . . . . . . . . . 8W-12-4
I ntermi ttent Wi per Swi tch . . . . . . . . . . . . . . . 8W-12-4
Key-I n Swi tch/Hal o Lamp . . . . . . . . . . . . 8W-12-12, 22
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Lamp Outage Modul e . . . . . . . . . . . . . 8W-12-5, 15, 20
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . 8W-12-17
Left Courtesy Lamp . . . . . . . . . . . . . . . . 8W-12-12, 22
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Left Front Park Lamp . . . . . . . . . . . . . . . . . 8W-12-15
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . 8W-12-13, 21
Li ftgl ass Li mi t Swi tch . . . . . . . . . . . . . . . . . . 8W-12-8
Memory Seat Modul e . . . . . . . . . . . . . . . . . . 8W-12-18
Overhead Consol e . . . . . . . . . . . . . . . . 8W-12-7, 13, 21
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Park/Neutral Posi ti on Swi tch . . . . . . . . . . 8W-12-6, 17
Passenger Door Modul e . . . . . . . . . . . . . . . . . 8W-12-7
Passenger Lumbar Swi tch . . . . . . . . . . . . . . 8W-12-18
Passenger Power Seat Swi tch . . . . . . . . . . . . 8W-12-18
Passenger Seat Heater Control Modul e . . 8W-12-10, 18
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . 8W-12-8, 11
Power Antenna . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Power Antenna Rel ay . . . . . . . . . . . . . . . . . . 8W-12-11
Power Di stri buti on Center . . . . . . . . . . . . 8W-12-5, 20
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16
Radi o . . . . . . . . . . . . . . . . . . . . . . 8W-12-3, 11, 15, 16
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . 8W-12-9
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8W-12-8
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . . . 8W-12-4
Reci rcul ati on Door Actuator . . . . . . . . . . . . . 8W-12-10
Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-12-17
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . 8W-12-12, 22
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Ri ght Front Park Lamp . . . . . . . . . . . . . . . . 8W-12-15
Ri ght Front Si de Marker Lamp . . . . . . . . . . 8W-12-17
Ri ght Si de Repeater . . . . . . . . . . . . . . . . . . . 8W-12-17
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . 8W-12-13, 21
Shi ft I nterl ock . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Speed Proporti onal Steeri ng Modul e . . . . . . . . 8W-12-6
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-12-7
Sunroof Control Modul e . . . . . . . . . . . . . . 8W-12-5, 21
Sunroof Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Swi tch Pod . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . . . . 8W-12-8
Turn Si gnal /Hazard Warni ng Swi tch . . . . 8W-12-11, 17
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . 8W-12-12
Vehi cl e I nformati on Center . . . . 8W-12-6, 11, 15, 16, 19
Vehi cl e Speed Control /Horn Swi tch . . . . . . . . 8W-12-23
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . . . . 8W-12-4
ZG 8W - 12 JUNCTION BLOCK 8W - 12 - 1
6 5
4
3
2 1
H
I
5
2
3 1
4
86
C
85
87
30
30
87
85
A
86
86
B
85
87
30
30
87
85
E
86
86
F
85
87
30
30
87
85
D
86
2 1
3
12
11
10
9
8 3
4
5
6
7
2
1
ENGINE
C
30
85 86
87
G
3 1
2 4
ENGINE
B
A
ENGINE
1
2
7
6
5
4
3 8
9
10
11
12 1 2
6 3 4 5
9 10 8 7
BODY A
B BODY
8 9 11 10
5 4 3 6
2 1
7
12
10A
20A
15A
15A 15A
15A
20A
15A 10A
10A
10A
10A 15A
15A
15A
10A
15A
10A
10A 15A
10A
20A
19
13
7
1 2
8
14
20
3
9
15
21
4
10A
16
22
5
11A
17
6
12A
18
CB1 20A
1 2
2 1
20A CB2
CB3 20A
1 2
2 6 10
5
4
3 1 7
8
9
2 6 10
9 5
4 8
7 3 1
I/P
I/P A
B E I/P
1
4 9
10 5
6 11
12 7
2
2
7 12
11 6
5 10
9 4
1
I/P D
8 3
3 8
3 1
2 4
I/P C
3 8
2
7 12
11 6
5 10
9 4
1
O/H
O/H
1
4 9
10 5
6 11
12 7
2
8 3
8 3
G I/P
1
4 9
10 5
6 11
12 7
2
AUTO
HEADLAMP
RELAY
PARK
LAMP
RELAY
POWER
ANTENNA
RELAY
(EXPORT ONLY)
COUTESY
LAMP
RELAY
ELECTRONIC
FLASHER
CIGAR
LIGHTER
RELAY
(NOT USED)
FOG
LAMP
RELAY
REAR
WINDOW
DEFOGGER
RELAY
SEE PAGE 8W-12-25 FOR JUNCTION BLOCK PIN-OUT INFORMATION
TOP OF
JUNCTION BLOCK
8W - 12 - 2 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01201
10A
FUSE
1
15A
FUSE
2
C7
1 4
C7
RUN-ACC A31
C1 6
RADIO
X12
18
RD/GY
A31
18
RD/BK
87
30 86
15A
FUSE
14
C4
3
BLOCK
JUNCTION
C4 4
BATT F61
1
LIGHTER
CIGAR
F30
18
RD/DB
C10
9
NOT
USED
CIGAR
LIGHTER
RELAY
BLOCK
JUNCTION
(8W-12-2)
(8W-12-2)
(8W-41-3)
(8W-10-9) (8W-10-9)
(8W-41-3)
(8W-47-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 3
ZGR01202 J978W-3
C10
5
10A
FUSE
3
2
C10
V23
20
BR/PK
V23
18
BR/PK
C2 15
MODULE
CONTROL
BODY
2
SWITCH
WASHER
WIPER/
REAR
RUN-ACC A31
20A
1
BREAKER
CIRCUIT
12
C1
S122
WINDSHIELD
WIPER
MOTOR
1
C1
C2 C3
(IN PDC)
RELAY
WIPER
INTERMITTENT
F86 16LG/RD
V6
16
DB
F18 C234
V6
16
DB
7 8
V6
16
DB
V6
16
DB
SWITCH)
MULTI-FUNCTION
(PART OF
SWITCH
WIPER
INTERMITTENT
S207
C5
G10
C235
G20
MODULE
CONTROL
BODY
C2 23
V18
20
YL/LG
V18
20
YL/LG
C4
7
4
INTERMITTENT
WIPER
SWITCH
(PART OF
MULTI-FUNCTION
SWITCH)
F86
16
LG/BK
F86
16
LG/BK
5 C231
F86
16
LG/BK
TO
S320
A
(8W-12-5)
LG/RD
F86
16
DIESEL GAS
F86
LG/RD
18
DIESEL
LG/RD LG/RD
16
F86
GAS
18
F86
LG/RD
DIESEL GAS
LG/RD
16
F86
18
F86
JUNCTION
BLOCK
(8W-53-3)
(8W-10-9)
(8W-53-2)
(8W-45-7)
(8W-53-2)
(8W-53-3)
(8W-53-4)
(8W-45-2)
(8W-12-2)
8W - 12 - 4 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01203
FROM
C231
F86
16
LG/BK
F86
16
LG/BK
F86
16
LG/BK
4 C371
F86
16
RD/YL
8
3
SUNROOF
CONTROL
MODULE
SWITCH
SUNROOF
10A
FUSE
4
C14
2
ST-RUN A21
1
C2
A16
18
FUSE
15A
A15
CENTER
DISTRIBUTION
POWER
A21
12
DB/GY
17
AIRBAG
CONTROL
MODULE
10A
FUSE
5
7
C13 C9
7
C13
7
10
LAMP
OUTAGE
MODULE
FUSED
IGN.
(ST-RUN)
G5
18
DB/WT
F87
18
WT/PK
F87
20
BK/WT
F87
20
BK/WT
F87
20
BK/WT
S215
5
INSTRUMENT
CLUSTER
2
INTERLOCK
SHIFT
NOT
USED
S320
A
(8W-12-4)
FUSED
IGN.
(ST-RUN)
C1
(DIESEL) (GAS)
CLUSTER
INSTRUMENT
5
BK/WT
20
F87
JUNCTION
BLOCK
(8W-40-5)
(8W-10-8)
(8W-31-5) (8W-40-5)
(8W-51-2)
(8W-43-2)
(8W-10-3)
(8W-10-13)
(8W-10-14)
(8W-64-2)
(8W-64-2)
(8W-12-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 5
ZGR01204 J978W-3
C8
1
15A
FUSE
6
RUN A22
F83
18
YL/DG
S212
F83
18
YL/DG
12
C235
18
F83
18
YL/DG
F83
18
YL/DG
S119
F83
18
YL/DG
SPEED
PROPORTIONAL
STEERING
F83
18
YL/DG
8 C132
F83
18
YL/DG
3
SWITCH
POSITION
NEUTRAL
PARK/
8
MODULE
STEERING
PROPORTIONAL
SPEED
F83
20
YL/DG
OTHERS
16
F83
18
YL/DG YL/DG
18
F83
16
GRAPHIC
DISPLAY
MODULE
VEHICLE
INFORMATION
CENTER
MINI
OVERHEAD
CONSOLE CONSOLE
OVERHEAD
FLASHER
ELECTRONIC
FUSED
IGN.
(RUN)
2
3
C15
OVERHEAD
CONSOLE OTHERS
F83
20
YL/DG
F83
20
BK/VT
B
(8W-12-7)
TO
S323
C
(8W-12-7)
AUTOMATIC
DAY/
NIGHT
MIRROR
TO
SWITCH
LAMP
(DIESEL)
1
YL/DG
F83
18
BACK-UP
C131 13
YL/DG
F83
18
18
F83
YL/DG
G12
C235
5
18
YL/DG
F83
HEADLAMP
SWITCH
LEVELING
G18
JUNCTION
BLOCK
(8W-50-11)
(8W-51-5)
(8W-10-8)
(8W-52-2)
(8W-52-6)
(8W-46-4) (8W-46-2)
(8W-65-2) (8W-30-10)
(8W-12-2)
8W - 12 - 6 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01205
F83
20
BK/VT
F83
20
YL/DG
F83
20
BK/VT
S323
1
MIRROR
NIGHT
DAY/
AUTOMATIC
F83
20
YL/DG
1
CONSOLE
OVERHEAD
C14
7
BATT A250
15A
FUSE
9
30A
2
BREAKER
CIRCUIT
3
C10
L16
18
RD/LG
6
STOP
LAMP
SWITCH
9
C14
F81
10
TN
F81
12
TN
3 C334 3 C351
F81
12
TN
F81
12
TN
12
DRIVER
DOOR
MODULE MODULE
DOOR
PASSENGER
12
C
(8W-12-6)
JUNCTION
BLOCK
FROM
B
(8W-12-6)
FROM
BLOCK
JUNCTION
C1
FUSED
B (+)
C1
JUNCTION
BLOCK
(8W-44-6)
(8W-44-7)
(8W-10-10)
(8W-60-3)
(8W-61-3)
(8W-60-2)
(8W-61-2)
(8W-33-2)
(8W-49-2)
(8W-12-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 7
ZGR01206 J978W-3
20A
FUSE
8
C14
8
BATT A250
F70
14
PK/BK
F70
14
PK/BK
2
C323
S336
F70
16
PK/BK
F70
16
PK/BK
F70
16
PK/BK
F70
16
PK/BK
1
REAR
WIPER
MOTOR
A
LIFTGLASS
LIMIT
SWITCH
LIFTGLASS OTHERS
D
CONNECTOR
TOW
TRAILER
AFTERMARKET
F70
18
PK/BK
A
F70
16
PK/BK
BREAKER
CIRCUIT
TOW
TRAILER
S315
7
FUSE
20A
8
C13
2
F75
16
VT
F75
16
VT
17 C1 C1
POWER
AMPLIFIER
(PREMIUM)
S318
F75
14
VT
C4
8
F75
18
VT
3
INSTRUMENT
CLUSTER
F75
18
VT
16
LINK
DATA
CONNECTOR
F75
18
VT
1
LED
VTSS
SENSOR/
LIGHT
HEADLAMP
AUTOMATIC
F75
18
VT
S201
9
C4
F75
18
VT
C2 8
MODULE
CONTROL
BODY
F70
16
PK/BK
6 C372
7
JUNCTION
BLOCK
(8W-10-10)
(8W-45-4)
(8W-50-5)
(8W-30-2)
(8W-30-30)
(8W-40-5)
(8W-47-10)
(8W-54-2)
(8W-54-5)
(8W-54-4)
(8W-61-5) (8W-53-4)
(8W-12-2)
8W - 12 - 8 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01207
C6
3
BATT A900
85 87
30 86
REAR
WINDOW
DEFOGGER
RELAY
1
C9 C10
8
C14
20
WT/RD
C2 14
10A
FUSE
10
C15
12
BK/WT
1 C301
C15
12
BK/WT
2
C322
C15
12
BK/LB
C15
12
BK
LIFTGLASS OTHERS
C15
12
BK/LB
S332
REAR
WINDOW
DEFOGGER DEFOGGER
WINDOW
REAR
C16
20
LB/YL
10
SWITCH
DEFOGGER
WINDOW
REAR
2
C13 C13
3
10A
FUSE
11
RUN A22
C13
6
F12
20
DB/WT
23
CONTROLLER
ANTI-LOCK
BRAKE
NOT
USED
MODULE
CONTROL
BODY
USED
NOT
3
12
C15
BK/LB
WINDOW
REAR
DEFOGGER
C322 2
DIESEL GAS
JUNCTION
BLOCK
(8W-48-2) (8W-45-3)
(8W-10-4) (8W-10-8)
(8W-35-2)
(8W-48-2)
(8W-48-2) (8W-48-2)
(8W-12-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 9
ZGR01208 J978W-3
10A
FUSE
12
C9
9
RUN A22
F71
20
PK/DG
F71
20
PK/DG
F C206
F71
20
PK/DG
F71
20
PK/DG
2
ACTUATOR
DOOR
BLEND
5
RECIRCULATION
DOOR
ACTUATOR
F71
20
PK/DG
4 C302
F71
18
PK/DG
4 C335 6 C329
5
POD
SWITCH
F71
20
PK/DG
S317
F71
18
PK/DG
F71
18
PK/DG
F87
18
PK/DG
F87
18
WT/BK
1 1
MODULE
CONTROL
HEATER
SEAT
PASSENGER DRIVER
SEAT
HEATER
CONTROL
MODULE
S218
4
C9
F71
20
DG/PK
6
A/C
HEATER
CONTROL
C12
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
F71
20
DG/PK
F71
20
DG/PK
MANUAL
A/C
HEATER ATC
ATC HEATER
A/C
MANUAL
C2
JUNCTION
BLOCK
(8W-42-7)
(8W-10-8)
(8W-42-9)
(8W-42-5)
(8W-63-14) (8W-63-13)
(8W-44-11)
(8W-42-9)
(8W-12-2)
8W - 12 - 10 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01209
C5
4
15A
FUSE
13
FLASHER
ELECTRONIC
5
1
FUSED
B(+)
GROUND
BATT A7
5 1 4
2 3
(EXPORT)
2 DOWN
1 UP
RELAY
ANTENNA
POWER
6
1 2 2 1
C3
1
RADIO
X60
20
DG/RD
3
C11 C11
2
C11
1
5 C5 C14 4
8
C1
AMPLIFIER
POWER
X60
18
DG/RD
Z1
18
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
2 C301
Z1
14
BK
G304
S202
S216
S220
POWER
ANTENNA
(EXPORT)
X14
20
WT
X16
20
GY
X17
20
DG
3 4
TURN
SIGNAL
5
C7 C5
1
L5
18
OR/BK
L12
18
VT/TN
17 13
SWITCH
HAZARD
SIGNAL/
TURN
RADIO
12V
OUTPUT
RADIO
12V
OUTPUT
WARNING
SIGNAL
HAZARD
OUTPUT
C1
DG/RD
14
18
X60
12V
RADIO
POWER
AMPLIFIER
LTD PREMIUM
INFORMATION
VEHICLE
CENTER
L5
18
OR/BK
4
(PART OF
MULTI-FUNCTION
SWITCH)
JUNCTION
BLOCK
(8W-46-6)
(8W-47-3)
(8W-47-3)
(8W-47-4)
(8W-47-3)
(8W-10-12)
(8W-15-17)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-47-3)
(8W-52-2)
(8W-52-2)
(8W-12-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 11
ZGR01210 J978W-3
10A
FUSE
16
C8
8
COURTESY
LAMP
RELAY
86
M1
20
PK
1
GLOVE
BOX
LAMP
1
C1
1 C159
1
LAMP
UNDERHOOD
A
A
B
4
RIGHT
COURTESY
LAMP
LAMP
COURTESY
LEFT
LAMP
HALO
SWITCH/
KEY-IN
LAMP
CARGO
M1
18
PK
M1
18
PK
6
C8
3
C8
5
C13
11
C8
M1
20
PK
M1
20
PK
M1
20
PK
M1
20
PK
C15
9
M1
20
PK
TO
S321
BATT A7
D
(8W-12-13)
JUNCTION
BLOCK
(8W-10-12)
(8W-44-5)
(8W-44-2)
(8W-44-2)
(8W-44-2)
(8W-44-2)
(8W-44-2)
(8W-44-8)
(8W-12-2)
8W - 12 - 12 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01211
M1
20
PK
A
LAMP
VANITY
VISOR/
RIGHT
LEFT
VISOR/
VANITY
LAMP
A
M1
20
PK
M1
20
PK
DOME/
READING
LAMP
C
6
OVERHEAD
CONSOLE
M1
20
PK
S321
M1
20
PK
D
(8W-12-12)
JUNCTION
BLOCK
FROM
(8W-49-3)
(8W-44-3)
(8W-44-5)
(8W-44-5)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 13
ZGR01212 J978W-3
15A
FUSE
17
C10
10
85 87
30 86
PARK
LAMP
RELAY
BATT A6
10
C8 C9
11
15 16
SWITCH
HEADLAMP
9
C5
9
A6
14
RD/LB
366
16
PK/OR
L90
20
DB/RD
11
C10
C2 21 17 C1
PARK
LAMP
RELAY
CONTROL
PARK
LAMP
RELAY
OUTPUT
L90
20
DB/RD
L79
20
TN
E
(8W-12-15)
MODULE
CONTROL
BODY
TO
JUNCTION
BLOCK
JUNCTION
BLOCK
(8W-45-4)
(8W-10-11)
(8W-50-7)
(8W-12-2)
8W - 12 - 14 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01213
C13
4
L90
18
DB/RD
(OPTIONAL)
MODULE
OUTAGE
LAMP
3 4 5
L90 18DB/RD L90 18DB/RD
FROM
JUNCTION
BLOCK
OUTPUT
9
C3
L90
18
DB/RD
2 C102 2 C150
L90
18
DB/RD
L90
18
DB/RD
L90
18
DB/RD
L90
18
DB/RD
S103
L90
18
DB/RD
A
LAMP
PARK
FRONT
S410
FRONT
PARK
LAMP
A
DB/RD
18
L90
S415
11
VEHICLE
INFORMATION
CENTER
C8
5
L90
20
DB/RD
L90
20
DB/RD
4
RADIO
4
C8 C15
1 9
C8
E
(8W-12-14)
NOT
USED
PARK
LAMP
RELAY
OUTPUT OUTPUT
RELAY
LAMP
PARK
NOT
USED
RELAY
LAMP
PARK
C1
LEFT RIGHT
C1 C1 C1
JUNCTION
BLOCK
(8W-50-9) (8W-50-10)
(8W-47-2)
(8W-46-6)
(8W-51-2)
(8W-12-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 15
ZGR01214 J978W-3
15A
FUSE
19
C7
2
BATT A7
L11
16
LG/BK
21
HEADLAMP
DIMMER
SWITCH
20
FUSE
15A
12
C9
F60
20
WT/RD
C13
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
F60
20
RD/WT
C9
10
7
RADIO
5
C9
2 2
F60
20
WT/RD
F60
20
WT/RD
GRAPHIC
DISPLAY
MODULE
VEHICLE
INFORMATION
CENTER
PREMIUM
OVERHEAD
CONSOLE OTHERS
3
C13
15A
FUSE
21
C9
2
F38
18
OR
1
OUTLET
POWER
NOT
USED
F60
20
WT/RD
C1
JUNCTION
BLOCK
(8W-10-12)
(8W-41-3)
(8W-46-4) (8W-46-2)
(8W-47-2)
(8W-42-2)
(8W-50-2)
(8W-12-2)
8W - 12 - 16 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01215
11
WARNING
HAZARD
SIGNAL/
TURN
7
CLUSTER
INSTRUMENT
1
SWITCH
POSITION
NEUTRAL
PARK/
3
MIRROR
NIGHT
DAY/
AUTOMATIC
L10
18
BR/LG
6 C131
L10
18
BR/LG
C14
1
C1 2 7 C15
L10
20
BK/RD
5 C4 C4 1
L64
18
TN/DB
L64
18
TN/DB
L10
18
BR/LG
L10
18
BR/LG
3 C372
L10
18
BR/LG
3 C331
L10
18
BR/LG
7
CONNECTOR
TOW
TRAILER
FACTORY
3 C328
A
LEFT
BACK-UP
LAMP
L10
18
BR/LG
L10
18
BR/LG
A
C320 3
LAMP
BACK-UP
RIGHT
L10
18
BR/LG
L10
18
BR/LG
S311
11
C3
L64
18
TN/DB
L64
18
TN/DB
L64
18
TN/DB
S412
2 1
FRONT
SWITCH
RIGHT RIGHT
REPEATER
SIDE
JUNCTION
BLOCK
RIGHT
RIGHT
LAMP
MARKER
SIDE
FRONT
B
A
S413
TN/DB
18
L64
TN/DB
18
L64
FRONT
TURN
SIGNAL
LAMP
TURN
SIGNAL
C150 1
1 C150
SIDE
REPEATER
LAMPS OTHERS
(8W-44-6)
(8W-52-2)
(8W-51-6)
(8W-51-6)
(8W-54-4)
(8W-44-7)
(8W-40-4)
(8W-12-2)
(8W-52-3)
(8W-52-3)
(8W-52-8)
(8W-52-8)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 17
ZGR01216 J978W-3
C14
10
20A
3
BREAKER
CIRCUIT
JUNCTION
BLOCK
BATT A7
F35
16
RD
1 C335
F35
16
RD
F35
16
RD
F35
18
RD
5 2 3
SWITCH
SEAT
POWER
PASSENGER
MODULE
CONTROL
HEATER
SEAT
PASSENGER PASSENGER
LUMBAR
SWITCH
S405
12
C13
F35
16
RD
1 C329
F35
14
RD
F35
14
RD
10
MODULE
SEAT
MEMORY
19
F35
16
RD
F35
16
RD
2
DRIVER
SEAT
HEATER
CONTROL
MODULE
5
SWITCH
SEAT
POWER
DRIVER
F35
16
RD
F35
16
RD
3
F35
18
RD
DRIVER
LUMBAR
SWITCH
S403
FUSED
B (+)
FUSED
B (+)
C2 C2
(8W-10-12)
(8W-63-3)
(8W-63-8)
(8W-63-14)
(8W-63-2)
(8W-63-4)
(8W-63-13)
(8W-63-9)
(8W-12-2)
8W - 12 - 18 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01217
19 19
G28
20
LG/OR
G28
20
LG/OR
OTHERS
CONSOLE
OVERHEAD
PREMIUM
18
VEHICLE
INFORMATION
CENTER MODULE
DISPLAY
GRAPHIC
18
A A C212
G28
20
LG/OR
G28
20
LG/OR
G42
20
LB/RD
G42
20
LB/RD
C3
3
C5 6 2 C5
G28
20
LG/OR
11 C132
G28
20
LG/OR
3
SWITCH
DRIVE
WHEEL
FOUR
VEHICLE
INFORMATION
CENTER MODULE
DISPLAY
GRAPHIC
CONSOLE
PREMIUM
OVERHEAD
OTHERS
JUNCTION
BLOCK
(8W-46-3) (8W-46-5)
(8W-46-3)
(8W-46-5)
(8W-46-3) (8W-46-5)
(8W-12-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 19
ZGR01218 J978W-3
BATT F61
10A
FUSE
15
86 30
87
A16
A15
85
15
SWITCH
HEADLAMP
7 C7 C7 10 3 C7
L95
18
DG/YL
A
RELAY
LAMP
FOG
REAR
C7 6
1
LAMP
OUTAGE
MODULE
L96
20
LG/RD
L36
18
LG
L36
18
LG/OR
7 C307
JUNCTION
BLOCK
(8W-10-9)
(8W-50-7)
(8W-51-7)
(8W-12-2)
8W - 12 - 20 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01219
7
SUNROOF
CONTROL
MODULE
Z1
16
BK
1 C371
Z1
16
BK
20
GRAPHIC
DISPLAY
MODULE
Z1
20
BK
B
LAMP
VANITY
VISOR/
LEFT RIGHT
VISOR/
VANITY
LAMP
B
A
DOME/
READING
LAMP
Z1
20
BK
Z1
20
BK
Z1
20
BK
2
MIRROR
NIGHT
DAY/
AUTOMATIC
CONSOLE
OVERHEAD
Z1
20
BK
2
Z1
20
BK
S322
Z1
16
BK
F
(8W-12-22)
JUNCTION
BLOCK
TO
OVERHEAD
CONSOLE
4
M2
20
YL
M2
20
YL
B
DOME/
READING
LAMP
M2
20
YL
M2
20
YL
M2
20
YL
S334
OTHERS SUNROOF
G
(8W-12-22)
JUNCTION
BLOCK
TO H
(8W-12-22)
TO
BLOCK
JUNCTION
BASE PREMIUM
(8W-44-6)
(8W-44-3) (8W-64-2)
(8W-44-3)
(8W-49-3)
(8W-49-3)
(8W-44-5) (8W-44-5)
(8W-46-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 21
ZGR01220 J978W-3
B
LEFT
COURTESY
LAMP
M2
20
YL YL
20
M2
LAMP
COURTESY
RIGHT
B
3
A
LAMP
HALO
SWITCH/
KEY-IN
LAMP
CARGO
M2
20
YL
M2
20
YL
C5
4
C8 7 12 C8 2 C8 3 C14
G
(8W-12-21) H
(8W-12-21)
FROM
LAMP
READING
DOME/
M2
20
YL
M2
20
YL
C15 11
F
(8W-12-21)
C15 2
Z1
16
BK
FROM
S322
30
87
COURTESY
LAMP
RELAY
Z1
18
BK
S220
Z1
16
BK
S216
Z1
16
BK
S202
Z1
14
BK
2 C301
Z1
14
BK
G304
OTHERS SUNROOF
OVERHEAD
CONSOLE
FROM
JUNCTION
BLOCK
(8W-15-8)
(8W-15-18)
(8W-15-17)
(8W-15-17)
(8W-44-8)
(8W-44-5)
(8W-44-2)
(8W-44-2)
(8W-44-2)
(8W-12-2)
8W - 12 - 22 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01221
A5
(IN PDC)
C7
12
C3 1
7
C10
X4
20
GY/OR
X4
20
GY/OR
5
SWITCH
HORN
CONTROL/
SPEED
VEHICLE
C2 13
MODULE
CONTROL
BODY
X4
20
GY/OR
10A
FUSE
22
RUN A22
C13
1
AIRBAG
CONTROL
MODULE
20
FUSED
IGN.
(RUN)
F20
18
WT
RELAY
HORN
JUNCTION
BLOCK
(8W-43-2)
(8W-10-8)
(8W-45-3)
(8W-41-2)
(8W-41-2)
(8W-12-2)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 23
ZGR01222 J978W-3
C10
12
AUTOMATIC
HEADLAMP
RELAY RELAY
LAMP
FOG
85 87
30 86
85 87
30 86
BATT A6 BATT F62
8
C5
19
HEADLAMP
DIMMER
SWITCH
F34
16
TN/BK
11
SWITCH
HEADLAMP
F34 16TN/BK
714
20
BK/OR
C2 12
MODULE
CONTROL
BODY
C10
1
C2 22
MODULE
CONTROL
BODY
L95
20
DG/YL
L39
18
LB
L39
18
LB
2
LEFT
FOG
LAMP LAMP
FOG
RIGHT
2
S105
L39
18
LB
4
C1 C7
8
L39
20
LB
4
SWITCH
HEADLAMP
JUNCTION
BLOCK
(8W-45-5)
(8W-10-11) (8W-10-13)
(8W-50-7)
(8W-50-6) (8W-50-6)
(8W-45-5)
(8W-50-2)
(8W-50-2)
(8W-12-2)
8W - 12 - 24 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01223
FUSES
FUSE NO. SIZE FEED CIRCUIT
10A A31 12RD/BK X12 18RD/GY
A31 12RD/BK A31 18RD/BK
A31 12RD/BK
15A
3
V23 18BR/PK
V23 20BR/PK
4
10A
A21 12DB/GY 10A
5
G5 18DB/WT
A21 12DB/GY 10A
6
F87 20BK/WT
F83 20YL/DG
7
F83 20BK/VT
8
15A A22 12BK/OR
F75 18VT
F75 18VT
A250 10RD 20A
L16 18RD/LG 15A A250 10RD
F70 14PK/BK 20A A250 10RD
C15 12BK/WT 10A C16 20LB/YL
A22 12BK/OR 10A
F12 20DB/WT
F12 20DB/WT
F71 20PK/DG
10A A22 12BK/OR
15A
F71 20PK/DG
A7 12YL/RD INTERNAL
- -
F61 12WT/OR INTERNAL
MI 18PK
10A A7 12YL/RD
FUSED CIRCUIT
1
2
9
10
11
12
13
14
15
16
17
20
19
18
21
22
15A
NOT USED
15A
15A
NOT USED
15A
15A
10A
A7 12YL/RD
A7 12YL/RD
-
A6 14RD/LB
A22 12BK/OR
A7 12YL/RD
F60 20RD/WT
L11 16LG/BK
-
366 16PK/OR
M1 20PK (7 WIRES)
F20 18WT
F38 18OR
(3 WIRES)
F75 14VT
F87 18WT/PK
F83 18YL/DG
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 25
ZGR01224 J978W-3
20A
FEED CIRCUIT SIZE CIRCUIT BREAKER
1 *
A31 12RD/BK
30A
87
L36 18LG REAR FOG LAMP
86
L95 18DG/YL RELAY OUTPUT
L96 20LG/RD
85
CAVITY CIRCUIT FUNCTION
30
F61 16WT/OR
FUSED B(+) INTERNAL
30
FUNCTION CIRCUIT CAV
85
Z1 20BK GROUND
FUSED IGNITION SWITCH OUPUT (RUN) A31 RD/BK
86
87
FUSED IGNITION SWITCH OUTPUT (ACC/RUN) F30 18RD/DB
RELAY
LIGHTER
CIGAR
(B)
87A
- -
20A
A7 12YL/RD
A250 10RD
87A - -
NO.
FUSED CIRCUIT
F86 16LG/BK
F86 16LG/BK
2
3
F86 16LG/RD
F81 10TN
F81 12TN
35 16RD
F35 16RD
RELAYS
CIRCUIT BREAKERS
FUSED B(+)
GROUND
(A)
REAR
FOG LAMP
RELAY
A31 12 RD/BK
20A 1 ** F86 18 LG/BK
8W - 12 - 26 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01225
C15 BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
87
86
A900 OR/YL FUSED B(+)
C14 WT/RD
85
CAVITY CIRCUIT FUNCTION
30
A900 OR/YL FUSED B(+)
REAR WINDOW DEFOGGER RELAY CONTROL
FUSED B(+)
GROUND
FUNCTION CIRCUIT
-
87A
-
POWER ANTENNA DRIVER
RADIO 12 VOLT OUTPUT
POWER ANTENNA DOWN CONTROL
5
4
3
2
1
CAVITY
X16 GY
X14 WT
6 POWER ANTENNA UP CONTROL
X60 DG/RD
INTERNAL
Z1 BK
X17 GN
POWER
ANTENNA
RELAY
(H)
(EXPORT ONLY)
(G)
RELAY
DEFOGGER
WINDOW
REAR
INTERNAL
INTERNAL
L12 VT/TN
L5 OR/BK
Z1 BK
CAVITY
1
2
3
4
5
TURN SIGNAL
HAZARD SIGNAL
GROUND
CIRCUIT FUNCTION
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (RUN)
ELECTRONIC
FLASHER
(I)
ZG-RHD 8W-12 JUNCTION BLOCK 8W - 12 - 27
ZGR01226 J978W-3
CAVITY CIRCUIT FUNCTION
30 M2 YL
COURTESY LAMP RELAY OUTPUT
COURTESY LAMP RELAY CONTROL
M112 BR/LG 85
86 M1 PK FUSED B(+)
87 Z1 BK GROUND
- - 87A
COURTESY
LAMP
RELAY
(C)
(D)
RELAY
LAMP
FOG
87A - -
FOG LAMP RELAY OUTPUT L39 LB 87
FUSED B(+) F62 RD 86
85 L95 DG/YL
FOG LAMP RELAY CONTROL
FUSED B(+)
F62 RD 30
FUNCTION CIRCUIT CAVITY
CAVITY CIRCUIT FUNCTION
30 366 PK/OR
PARK LAMP FEED
PARK LAMP RELAY CONTROL
L79 TN 85
86 366 PK/OR PARK LAMP FEED
87 L90 DB/RD PARK LAMP RELAY OUTPUT
- - 87A
PARK
LAMP
RELAY
(E)
(F)
RELAY
HEADLAMP
AUTO
87A - -
AUTO HEADLAMP RELAY OUTPUT F34 TN/BK 87
FUSED B(+) A6 RD/LB 86
85 714 BK/OR AUTO HEADLAMP RELAY CONTROL
FUSED B(+) A6 RD/LB 30
FUNCTION CIRCUIT CAVITY
8W - 12 - 28 8W-12 JUNCTION BLOCK ZG-RHD
J978W-3 ZGR01227
8W-12 J UNCTION BLOCK
DESCRIPTION AND OPERATION
Thi s secti on covers the juncti on bl ock and al l ci r-
cui ts i nvol ved wi th i t. For addi ti onal i nformati on on
system operati on, pl ease refer to the appropri ate sec-
ti on of the wi ri ng di agrams.
ZG 8W - 12 JUNCTION BLOCK 8W - 12 - 29
8W-15 GROUND DISTRIBUTION
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Component Page
A/C Heater Control . . . . . . . . . . . . . . . . . . . . . 8W-15-8, 17
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . . . . . . . 8W-15-7
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . . . . . 8W-15-16
Automati c Temperature Control Modul e . . . . . . . . . . . 8W-15-8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Bl ower Power Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Body Control Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
Center Hi gh Mounted Stop Lamp No. 1 . . . . . . . . . . . 8W-15-9
Center Hi gh Mounted Stop Lamp No. 2 . . . . . . . . . . . 8W-15-9
Center Hi gh Mounted Stop Lamp No. 3 . . . . . . . . . . . 8W-15-9
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Control l er Anti -Lock Brake . . . . . . . . . . . . . . . . . . . 8W-15-8
Courtesy Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-15-16
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
Dome/Readi ng Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
Downstream Heated Oxygen Sensor . . . . . . . . . . . . . 8W-15-7
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-15-12
Dri ver Heated Seat Back . . . . . . . . . . . . . . . . . . . 8W-15-15
Dri ver Heated Seat Cushi on . . . . . . . . . . . . . . . . . 8W-15-15
Dri ver Lumbar Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . . . . . . 8W-15-15
Dri ver Seat Heater Control Modul e . . . . . . . . . . . . . 8W-15-15
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
El ectroni c Fl asher . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
Engi ne Cool ant Level Sensor . . . . . . . . . . . . . . . . . . 8W-15-7
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-15-8
Factory Trai l er Tow Connector . . . . . . . . . . . . . . . . . 8W-15-9
Fl oor Consol e Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Four Wheel Dri ve Swi tch . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
G305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Graphi c Di spl ay Modul e . . . . . . . . . . . . . . . . . 8W-15-17, 18
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . . . . 8W-15-18
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16, 17
Key-I n Swi tch/Hal o Lamp . . . . . . . . . . . . . . . . . . . 8W-15-17
Lamp Outage Modul e . . . . . . . . . . . . . . . . . . . . . 8W-15-12
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Component Page
Left Door Courtesy Lamp . . . . . . . . . . . . . . . . . . . 8W-15-12
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
Left Front Park Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
Left Front Turn Si gnal Lamp . . . . . . . . . . . . . . . . 8W-15-4, 5
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
Left Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Left Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Left Rear Power Wi ndow Swi tch . . . . . . . . . . . . . . . 8W-15-15
Left Rear Turn Si gnal Lamp . . . . . . . . . . . . . . . . . . 8W-15-9
Left Si de Repeater . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-16
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Li ftgate Cyl i nder Lock Swi tch . . . . . . . . . . . . . . . . 8W-15-10
Li ftgl ass Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Li ftgl ass Rel ease Sol enoi d . . . . . . . . . . . . . . . . . . . 8W-15-10
Mass Ai r Fl ow Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Memory Seat Modul e . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Msa Control l er . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
Passenger Door Modul e . . . . . . . . . . . . . . . . . . . . 8W-15-14
Passenger Heated Seat Back . . . . . . . . . . . . . . . . . 8W-15-13
Passenger Heated Seat Cushi on . . . . . . . . . . . . . . . 8W-15-13
Passenger Lumbar Swi tch . . . . . . . . . . . . . . . . . . . 8W-15-13
Passenger Power Seat Swi tch . . . . . . . . . . . . . . . . 8W-15-13
Passenger Seat Heater Control Modul e . . . . . . . . . . . 8W-15-13
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Powertrai n Control Modul e . . . . . . . . . . . . . . . . . 8W-15-2, 3
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . 8W-15-4, 5
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
Ri ght Door Courtesy Lamp . . . . . . . . . . . . . . . . . . 8W-15-14
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Ri ght Front Park Lamp . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . . . . . . 8W-15-6, 7
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Ri ght Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-11
Ri ght Rear Power Wi ndow Swi tch . . . . . . . . . . . . . . 8W-15-14
Ri ght Rear Turn Si gnal Lamp . . . . . . . . . . . . . . . . 8W-15-11
Ri ght Si de Repeater . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . . . . 8W-15-16
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Speed Proporti onal Steeri ng Modul e . . . . . . . . . . . . . 8W-15-5
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 18
Sunroof Control Modul e . . . . . . . . . . . . . . . . . . . . 8W-15-16
Swi tch Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Trai l er Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 8
Upstream Heated Oxygen Sensor . . . . . . . . . . . . . . . 8W-15-7
Vehi cl e I nformati on Center . . . . . . . . . . . . . 8W-15-12, 17, 18
Vehi cl e Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-15-8
Vehi cl e Speed Control /Horn Swi tch . . . . . . . . . . . . . 8W-15-18
Wi ndshi el d Washer Pump Motor . . . . . . . . . . . . . . 8W-15-4, 5
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
Wi per Fl ui d Level Sensor . . . . . . . . . . . . . . . . . . 8W-15-4, 5
ZG 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1
BATTERY GENERATOR
Z0
6
BK
Z0
8
BK
Z0
6
BK
G101
Z0
6
BK
G100
S126
4
DATA
LINK
CONNECTOR
5
G103
H11 H12 C236
Z1
18
BK
1 2 C132
Z1
18
BK
Z1
18
BK
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
C1
A31 A32
C1
MODULE
CONTROL
POWERTRAIN
G104
Z12
14
BK/TN
Z12
14
BK/TN
1
(8W-20-2)
(8W-20-3)
(8W-30-2)
(8W-30-18)
(8W-30-19)
(8W-30-3)
8W - 15 - 2 8W-15 GROUND DISTRIBUTION
GAS ENGINES
ZG-RHD
J978W-3 ZGR01501
BATTERY
Z0
2
BK
G101
Z0
6
BK
G100
4
DATA
LINK
CONNECTOR
5
GROUND GROUND
G103
H11 H12 C236
Z1
18
BK
2 3 C132
Z1
18
BK
Z1
18
BK
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
C4
12 11
C4
MODULE
CONTROL
POWERTRAIN
GROUND GROUND
G104
Z12
16
BK/TN
Z12
16
BK/TN
46 24 1
CONTROLLER
MSA
Z12
14
BK/TN
Z12
16
BK/TN
Z12
16
BK/TN
Z12
10
BK/TN
S130
(8W-30-30)
(8W-30-31)
(8W-30-32)
(8W-30-22)
(8W-30-22)
ZG-RHD 8W-15 GROUND DISTRIBUTION
DIESEL ENGINE
8W - 15 - 3
ZGR01515 J978W-3
6 B
LAMP
PARK
FRONT FRONT
TURN
SIGNAL
LAMP
S149
Z1
18
BK
Z1
18
BK
Z1
18
BK
3 C102
Z1
18
BK
1 1
LEFT
FOG
LAMP
S109
HEADLAMP
LEFT
Z1
18
BK
Z1
16
BK
A
(8W-15-6)
TO
G106
Z1
16
BK
Z1
16
BK
G109
4
B
MOTOR
PUMP
WASHER
WINDSHIELD
WINDSHIELD
WIPER
MOTOR
4
2
MOTOR
PUMP
WASHER
REAR
SENSOR
LEVEL
FLUID
WIPER
B
16
BK
18
BK
18
BK
18
BK
Z2
20
BK
S121
12
BK
Z2 Z2 Z2 Z2
Z2
LEFT LEFT STOP
LAMP
C235
G8
DB/LG
20
V30
Z1
18
BK
2
UNDERHOOD
LAMP
C159 2
BK
Z1
18
Z1
18
BK
1
LEFT
REPEATER
SIDE
SWITCH
G2
(8W-52-8)
(8W-44-2)
(8W-33-2)
(8W-33-4)
(8W-50-9)
(8W-46-6)
(8W-53-5)
(8W-53-5)
(8W-53-3)
(8W-53-2)
(8W-50-3)
(8W-50-6)
(8W-52-3)
8W - 15 - 4 8W-15 GROUND DISTRIBUTION
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR01502
G B
LAMP
PARK
FRONT FRONT
TURN
SIGNAL
LAMP
S149
Z1
18
BK
Z1
18
BK
Z1
18
BK
3 C102
Z1
18
BK
1 1
LEFT
FOG
LAMP
S109
HEADLAMP
LEFT
Z1
18
BK
Z1
16
BK
K
(8W-15-7)
TO
G106
Z1
16
BK
Z1
16
BK
G109
10
MODULE
STEERING
PROPORTIONAL
SPEED
B
MOTOR
PUMP
WASHER
WINDSHIELD
WINDSHIELD
WIPER
MOTOR
4
2
MOTOR
PUMP
WASHER
REAR
SENSOR
LEVEL
FLUID
WIPER
B
16
BK
18
BK
18
BK
18
BK
Z2
20
BK
S121
12
BK
Z2 Z2 Z2 Z2
Z2
LEFT LEFT
(8W-50-9)
(8W-46-6)
(8W-53-5)
(8W-53-5)
(8W-53-3)
(8W-53-2)
(8W-65-2)
(8W-50-3)
(8W-50-6)
(8W-52-3)
ZG-RHD 8W-15 GROUND DISTRIBUTION
GAS ENGINES
8W - 15 - 5
ZGR01516 J978W-3
1
SWITCH
DRIVE
WHEEL
FOUR
MASS
AIR
FLOW
MODULE
1
2
HEATER
FUEL
S134
Z1
20
BK
1
HEADLAMP
RIGHT
Z1
16
BK
1
REPEATER
SIDE
RIGHT
Z1
18
BK
Z1
12
BK
10 C131
Z1
12
BK
1
RIGHT
FOG
LAMP
2
NO. 1
HORN
HORN
NO. 2
2
Z1
16
BK
Z1
16
BK
Z1
18
BK
Z1
10
BK
Z1
18
BK
3 C150
Z1
18
BK
B
LAMP
PARK
FRONT
RIGHT
TURN
SIGNAL
LAMP
G
S152
Z1
18
BK
Z1
18
BK
G106
Z1
16
BK
A
(8W-15-4)
FROM
S109
S104
FRONT
RIGHT
BK
Z1
20
BK
Z1
14
Z1
18
BK
4
SOLENOID
EGR
(8W-30-28)
(8W-39-6)
(8W-41-2)
(8W-50-10)
(8W-52-3)
(8W-39-6)
(8W-41-2)
(8W-50-6) (8W-52-8)
(8W-50-3)
(8W-30-28)
(8W-30-26)
(8W-46-3)
(8W-46-5)
8W - 15 - 6 8W-15 GROUND DISTRIBUTION
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR01503
2
SENSOR
OXYGEN
HEATED
UPSTREAM
DOWNSTREAM
HEATED
OXYGEN
SENSOR
2
1
SWITCH
DRIVE
WHEEL
FOUR
S130
Z12
18
BK/TN
Z12
18
BK/TN
Z12
20
BK/TN
G105
Z12
16
BK/TN
1
HEADLAMP
RIGHT
Z1
16
BK
2
SENSOR
LEVEL
COOLANT
ENGINE
Z1
16
BK
Z1
18
BK
4 C144
2
SWITCH
PRESSURE
HIGH
A/C
Z1
18
BK
1
RIGHT
FOG
LAMP
2
NO. 1
HORN
HORN
NO. 2
2
Z1
16
BK
Z1
16
BK
Z1
18
BK
Z1
14
BK
Z1
18
BK
3 C150
Z1
18
BK
B
LAMP
PARK
FRONT
RIGHT
TURN
SIGNAL
LAMP
G
S152
Z1
18
BK
Z1
18
BK
G106
Z1
16
BK
K
(8W-15-5)
FROM
S109
S104
FRONT
RIGHT
Z1
18
BK
SIDE
REPEATER
RIGHT
1
(8W-52-8)
(8W-39-6)
(8W-41-2)
(8W-50-10)
(8W-52-3)
(8W-39-6)
(8W-41-2)
(8W-50-6)
(8W-42-12)
(8W-46-6)
(8W-50-3)
(8W-46-3)
(8W-46-5)
(8W-30-13)
(8W-30-14)
(8W-30-13)
(8W-30-14)
ZG-RHD 8W-15 GROUND DISTRIBUTION
GAS ENGINES
8W - 15 - 7
ZGR01517 J978W-3
D7
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
5
BLOWER
POWER
MODULE
2
MOTOR
BLOWER
P C206
Z4
20
PK
Z4
20
BK
Z4
18
BK
Z4
12
BK
CONTROL
HEATER
A/C
4
Z4
12
BK
J C206
C1
14
DG
Z4
12
BK
S226
ATC MANUAL
A/C
2 C160
Z4
12
BK
2 C159
Z1
18
BK
2
LAMP
UNDERHOOD
4
SERVO
CONTROL
SPEED
VEHICLE
Z4
20
BK
Z4
18
BK
Z4
10
BK
G107
8 24
Z2
12
BK
Z2
12
BK
S125
G108
S124
Z2
12
BK
BRAKE
ANTI-LOCK
CONTROLLER
C1
(GAS)
(GAS)
BK
Z4
20
D11
(DIESEL)
FUEL
HEATER
RELAY
(IN PDC)
BK
20
Z4
(DIESEL)
(IN PDC)
RELAY
MOTOR
C10
STARTER
ENGINE
(8W-21-3)
(8W-30-27)
(8W-35-2)
(8W-33-2)
(8W-44-2)
(8W-42-5)
(8W-42-3)
(8W-42-3)
(8W-42-2)
8W - 15 - 8 8W-15 GROUND DISTRIBUTION ZG-RHD
J978W-3 ZGR01504
2
NO. 1
LAMP
STOP
MOUNTED
HIGH
CENTER CENTER
HIGH
MOUNTED
STOP
LAMP
NO. 2
2 2
NO. 3
LAMP
STOP
MOUNTED
HIGH
CENTER
Z1 20BK Z1 20BK
Z1
20
BK
B C359
Z1
18
BK
B
(8W-15-11)
TO
C326
1
9 C331
Z1
12
BK
Z1
12
BK
2
2
2
Z1
18
BK
Z1
18
BK
Z1
18
BK
G
LEFT
BACK-UP
LAMP
G
G
LAMP
STOP
TAIL/
LEFT
B
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
4 C328
Z1
18
BK
D
(8W-15-12)
TO
S314
C372 8
Z1
12
BK
Z1
12
BK
E
(8W-15-12)
TO
S314
S411 S330
RELAY
LAMP
STOP
TOW
TRAILER
TRAILER
TOW
LEFT
TURN
RELAY
TRAILER
TOW
RIGHT
TURN
RELAY
LAMP
SIGNAL
TURN
LEFT
REAR
FOG
LAMP
REAR
FACTORY
TRAILER
TOW
CONNECTOR
LEFT
(8W-51-7)
(8W-52-5)
(8W-52-7)
(8W-54-3)
(8W-54-3)
(8W-54-3)
(8W-51-4)
(8W-51-6)
(8W-54-3)
(8W-51-5) (8W-51-5) (8W-51-5)
ZG-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 9
ZGR01505 J978W-3
2
LEFT
LICENSE
LAMP LAMP
LICENSE
RIGHT
2
S419
Z1
20
BK
Z1
20
BK
Z1
20
BK
A C364
Z1
20
BK
3
REAR
WIPER
MODULE
Z1
14
BK
Z1
12
BK
REAR
WINDOW
DEFOGGER
2
SWITCH
LOCK
CYLINDER
LIFTGATE
1
LIFTGLASS
AJAR
SWITCH
Z1
20
BK
Z1
20
BK
1
SWITCH
AJAR
LIFTGATE
Z1
20
BK
2
LIFTGLASS
RELEASE
SOLENOID
Z1
14
BK
S328
J
(8W-15-11)
TO
C325
(8W-51-6) (8W-51-6) (8W-53-4)
(8W-48-2)
(8W-39-5)
(8W-44-14)
(8W-44-14)
(8W-61-5)
8W - 15 - 10 8W-15 GROUND DISTRIBUTION ZG-RHD
J978W-3 ZGR01506
G
LAMP
STOP
TAIL/
RIGHT
G
LAMP
FOG
REAR
RIGHT
REAR
SIGNAL
LAMP
G
G
RIGHT
BACK-UP
LAMP
S417
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
4 C320
Z1
18
BK
G300
Z1
12
BK
Z1
18
BK
2 C326
Z1
18
BK
FROM
C359
S316
2 C325
Z1
12
BK
Z1
12
BK
Z1
12
BK
TO
S314
B
(8W-15-9)
C
(8W-15-12)
J
(8W-15-10)
TO
S328
TURN
RIGHT
(8W-52-5)
(8W-52-7)
(8W-51-7)
(8W-51-6)
(8W-51-4)
ZG-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 11
ZGR01507 J978W-3
9
LAMP
OUTAGE
MODULE
VEHICLE
INFORMATION
CENTER
5
5 C307
G46
20
BK/LB
G46
20
BK/LB
9 C316
Z1
18
BK
Z1
18
BK
LAMP
OUTAGE
MODULE
OTHERS
7
DRIVER
DOOR
MODULE
Z1
12
BK
2
COURTESY
DOOR
LEFT
7
DRIVER
DOOR
MODULE
Z1
20
BK
Z1
12
BK
Z1
12
BK
1 C334
Z1
12
BK
FULL
OPTION
POWER
GROUP
G302
Z1
12
BK
FROM
S316 C328
FROM FROM
C372
Z1
12
BK
Z1
12
BK
Z1
18
BK
S314
S324
C
(8W-15-11)
D
(8W-15-9)
E
(8W-15-9)
C1
C1
C2
LAMP (8W-60-2)
(8W-61-2)
(8W-62-2)
(8W-60-2)
(8W-61-2)
(8W-62-2)
(8W-46-6) (8W-51-5)
8W - 15 - 12 8W-15 GROUND DISTRIBUTION ZG-RHD
J978W-3 ZGR01508
RADIO
Z5
16
BK
12
C305
9
Z5
14
BK/LB
Z5
14
BK/LB
Z5
14
BK/LB
10 11
AMPLIFIER
POWER
Z5
16
BK/LB
Z5
16
BK/LB
S309
10
AIRBAG
CONTROL
MODULE
G303
Z6
16
BK/PK
1
SWITCH
SEAT
POWER
PASSENGER
A
PASSENGER
HEATED
SEAT
BACK
7
MODULE
CONTROL
HEATER
SEAT
PASSENGER
Z1
18
BK
Z1
16
BK
Z1
18
BK
2 4
PASSENGER
LUMBAR
SWITCH
D
CUSHION
SEAT
HEATED
PASSENGER
Z1
18
BK
Z1
18
BK
Z1
20
BK
S406
Z1
14
BK
F
(8W-15-14)
TO
C335
PREMIUM
RADIO OTHER
C2 C2
(8W-63-12)
(8W-63-4)
(8W-63-13)
(8W-63-12)
(8W-63-9)
(8W-43-2)
(8W-47-10)
(8W-47-2)
ZG-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 13
ZGR01509 J978W-3
2
COURTESY
DOOR
RIGHT
7
PASSENGER
DOOR
MODULE
Z1
20
BK
Z1
12
BK BK
12
Z1
MODULE
DOOR
PASSENGER
7
Z1
12
BK
FULL
OPTION
POWER
GROUP
S325
1 C351
Z1
12
BK
6
WINDOW
POWER
REAR
RIGHT
FROM
S406
2 C335
Z1
14
BK
Z1
16
BK
D C345
Z1
16
BK
Z1
16
BK
S333
Z1
12
BK
G301
Z1
10
BK
TO
S304
F
(8W-15-13)
G
(8W-15-15)
SWITCH
C1 C1
LAMP
(8W-60-4)
(8W-44-2)
(8W-60-3)
(8W-61-3)
(8W-62-3)
(8W-60-3)
(8W-61-3)
(8W-62-3)
8W - 15 - 14 8W-15 GROUND DISTRIBUTION ZG-RHD
J978W-3 ZGR01510
S304
BK
20
Z1
BK
20
Z1
BK
16
Z1
BK
16
Z1
C343 D
BK
16
Z1
LEFT
REAR
POWER
WINDOW
SWITCH
6
MODULE
PUMP
FUEL
6
SWITCH
BELT
SEAT
2
LAMPS
CONSOLE
FLOOR
1
FROM
S333
Z1
12
BK
G305
Z1
10
BK
1 8
MEMORY
SEAT
MODULE
Z1
16
BK
Z1
16
BK
1
SWITCH
SEAT
POWER
DRIVER
Z1
16
BK
7
Z1
16
BK
MODULE
CONTROL
HEATER
SEAT
DRIVER
BK
20
Z1
D
BK
16
Z1
DRIVER
HEATED
SEAT
BACK
A
BK
18
Z1
BK
18
Z1
SWITCH
LUMBAR
DRIVER
4 2
CUSHION
SEAT
HEATED
DRIVER
2 C329
Z1
16
BK
Z1
14
BK
S402
G
(8W-15-14)
C2 C2
(8W-60-4)
(8W-30-16) (8W-45-4) (8W-44-11)
(8W-63-2)
(8W-63-8)
(8W-63-14)
(8W-63-11)
(8W-63-2)
(8W-63-11)
ZG-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 15
ZGR01511 J978W-3
1
SUNROOF
CONTROL
MODULE
2
CONSOLE
OVERHEAD
Z1
20
BK
Z1
16
BK
1 C371
Z1
16
BK
B
LAMP
VANITY
VISOR/
RIGHT
LEFT
VISOR/
VANITY
LAMP
B
Z1
20
BK
Z1
20
BK
A
Z1
20
BK
DOME/
READING
LAMP
2
MIRROR
NIGHT
DAY/
AUTOMATIC
Z1
20
BK
S322
C5
4
C15 2
Z1
16
BK
Z1
18
BK
H
(8W-15-17)
TO
S220
JUNCTION
BLOCK
5 87
COURTESY
LAMP
RELAY
ELECTRONIC
FLASHER
(8W-52-2)
(8W-44-8)
(8W-12-2)
(8W-44-7)
(8W-64-2)
(8W-44-3)
(8W-44-5)
(8W-44-5)
(8W-49-2)
8W - 15 - 16 8W-15 GROUND DISTRIBUTION ZG-RHD
J978W-3 ZGR01512
2
LIGHTER
CIGAR
4
C34
20
VT/WT
H C206
C34
20
VT/WT
Z1
18
BK
2
OUTLET
POWER
Z1
18
BK
2
GLOVE
BOX
LAMP
Z1
20
BK
3
C34
20
VT/WT
A/C
HEATER
CONTROL
2
ASH
RECEIVER
LAMP
Z1
20
BK
9
C7
Z1
18
BK
JUNCTION
BLOCK
H
(8W-15-16)
JUNCTION
BLOCK
FROM
Z1
18
BK
20
GRAPHIC
DISPLAY
MODULE
20
VEHICLE
INFORMATION
CENTER
Z1
20
BK
Z1
20
BK
OTHERS
2
POD
SWITCH
1
LAMP
HALO
SWITCH/
KEY-IN
1
INSTRUMENT
CLUSTER
S220
Z1
16
BK
Z1
20
BK
Z1
20
BK
Z1
20
BK
Z1
16
BK
I
(8W-15-18)
TO
S202
S216
ACTUATOR
DOOR
BLEND
CONSOLE
OVERHEAD
PREMIUM
85
CIGAR
LIGHTER
RELAY
C2
(8W-41-3)
(8W-44-11)
(8W-42-7)
(8W-40-2)
(8W-44-2)
(8W-46-4)
(8W-46-2)
(8W-12-2)
(8W-44-12)
(8W-42-5)
(8W-44-2)
(8W-41-3)
(8W-41-3)
ZG-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 17
ZGR01513 J978W-3
CONSOLE
OVERHEAD
MINI
CONSOLE
OVERHEAD
BK/OR
20
Z2
BK/OR
20
Z2
CENTER
INFORMATION
VEHICLE
3
MODULE
DISPLAY
3
2
Z2
20
BK/OR
INSTRUMENT
CLUSTER
4
VEHICLE
HORN
SWITCH
Z2
20
BK/OR
C1
16
MODULE
CONTROL
BODY
8
C3
Z2
20
BK/OR
Z2
18
BK/OR
S205
Z2
18
BK/OR
8 C307
Z2
18
BK/OR
S302
2 5
SWITCH
HEADLAMP
Z1
16
BK
Z1
16
BK
C2
24
MODULE
CONTROL
BODY
Z1
16
BK
2
STOP
LAMP
SWITCH
Z1
20
BK
I
(8W-15-17)
FROM
S216
Z1
16
BK
Z1
14
BK
2 C301
Z1
14
BK
Z2
18
BK/OR
G304
S202
GRAPHIC
SPEED
CONTROL/
LEVELING
SWITCH
1
HEADLAMP
BK
20
Z1
(8W-50-11)
(8W-33-2)
(8W-45-2)
(8W-50-5)
(8W-45-2)
(8W-33-3)
(8W-40-2)
(8W-46-2)
(8W-46-4)
8W - 15 - 18 8W-15 GROUND DISTRIBUTION ZG-RHD
J978W-3 ZGR01514
8W-15 GROUND DISTRIBUTION
DESCRIPTION AND OPERATION
Thi s secti on i denti fi es the grounds, spl i ces that
connect to those grounds, and the components that
connect those grounds. For addi ti onal i nformati on on
system operati on, refer to the appropri ate secti on of
the wi ri ng di agrams. For an i l l ustrati on of the phys-
i cal l ocati on of each ground, refer to group 8W-90.
ZG 8W - 15 GROUND DISTRIBUTION 8W - 15 - 19
8W-20 CHARGING SYSTEM
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Page
Automati c Shut Down Rel ay . . . . . . . . 8W-20-2, 4, 5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Engi ne Starter Motor . . . . . . . . . . . . . . . 8W-20-2, 3
Engi ne Starter Motor Rel ay . . . . . . . . . . . . 8W-20-5
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-5
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-5
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4, 5
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Generator . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-5
Component Page
MSA Control l er . . . . . . . . . . . . . . . . . . . . . . 8W-20-4
Power Di stri buti on Center . . . . . . . . 8W-20-2, 3, 4, 5
Powertrai n Control Modul e . . . . . . . 8W-20-2, 3, 4, 5
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-5
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-5
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-5
S129 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4, 5
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
Transmi ssi on Control Rel ay . . . . . . . . . . . . 8W-20-3
ZG 8W - 20 CHARGING SYSTEM 8W - 20 - 1
BK
6
Z0
G100
BATTERY
MOTOR
STARTER
ENGINE
RD
2
A0
G101
CENTER
DISTRIBUTION
POWER
M2
M1
175A
FUSE
1
Z0
2
BK
A11
6
RD/BK
GENERATOR
FIELD
DRIVER
MODULE
CONTROL
POWERTRAIN
20 C4
3
1
K20
18
DG/YL
GENERATOR
16
B17
DG/OR
12 C131
A142
DG/OR
16
A142
DG/OR
16
A142
RELAY
SHUT
(IN PDC)
AUTOMATIC
S129
DOWN
(8W-70-7)
(8W-30-5)
(8W-10-4)
(8W-10-3)
(8W-21-3)
(8W-30-23)
8W - 20 - 2 8W-20 CHARGING SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR02001
BK
6
Z0
G100
BATTERY
MOTOR
STARTER
ENGINE
RD
6
A0
G101
Z0
6
BK
CENTER
DISTRIBUTION
POWER
M2
M1
175A
FUSE
1
Z0
6
BK
S126
A11
6
RD/BK
S137
A11
10
DG
A8
A10
(IN PDC)
RELAY
CONTROL
GENERATOR
FIELD
DRIVER
DG
18
K20
DG/VT
18
K72
C3 C25
MODULE
CONTROL
POWERTRAIN
B10 C2 B30 C2
TRANSMISSION
RELAY
CONTROL
G101
Z0
8
BK
Z0
6
BK
S126
1
3
2
K20
18
DG
2 C144
K20
18
DG
C132 6
K72
18
DG/VT
T66
20
BR/OR
7 C132
T66
20
BR/OR
GENERATOR
SOURCE
GENERATOR
FIELD
1
TRANSMISSION
(8W-15-2)
(8W-15-2)
(8W-15-2)
(8W-15-2)
(8W-31-2)
(8W-30-3)
(8W-10-4)
(8W-10-3)
(8W-21-4)
ZG-RHD 8W-20 CHARGING SYSTEM
GAS ENGINES
8W - 20 - 3
ZGR02003 J978W-3
CENTER
DISTRIBUTION
POWER
A20
A19
25A
FUSE
20
F5
16
RD/YL
BATT A0
42
MSA
CONTROLLER
B17 B20
B18 B16
AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)
AUTOMATIC
SHUT
DOWN
RELAY
CONTROL
PK/BK
20
K900
A142
16
DG/OR
12 C131
DG/OR
16
A142
S129
A142
16
DG/OR
57
F5
RD/YL
16
C4
AUTOMATIC
CONTROL
RELAY
DOWN
SHUT
MODULE
CONTROL
POWERTRAIN
C132 14
20
PK/BK
K900
(8W-30-27)
(8W-10-3)
(8W-70-7)
(8W-30-27)
(8W-10-16)
(8W-10-3)
8W - 20 - 4 8W-20 CHARGING SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR02002
CENTER
DISTRIBUTION
POWER
A20
A19
20A
FUSE
20
F5
14
RD/YL
S100
F5
18
RD/YL
BATT A0
OR
20
F99
S101
OR
18
F99
18
FUSE
15A
A16
A15 7
14
40A
FUSE
8
A1
12
RD/WT
C6
(IN PDC)
RELAY
MOTOR
STARTER
ENGINE
C3 C3 C3 C12
POWERTRAIN
CONTROL
MODULE
B17 B20
B18 B16
AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)
AUTOMATIC
SHUT
DOWN
RELAY
CONTROL
A142
18
DG/OR PK/WT
18
K900
A142
18
DG/OR
4 C131
5.2L 4.0L
DG/OR
18
A142
S129
A142
18
DG/OR DG/OR
18
A142
S128
A142
18
DG/OR
IGNITION
COIL
2
OUTPUT
AUTOMATIC
RELAY
DOWN
SHUT
ST-RUN A21 (8W-10-8) (8W-10-3)
(8W-30-5)
(8W-70-7) (8W-70-7)
(8W-30-5)
(8W-21-4)
(8W-10-7) (8W-10-14)
(8W-10-15) (8W-10-16)
(8W-10-16)
(8W-10-3)
ZG-RHD 8W-20 CHARGING SYSTEM
GAS ENGINES
8W - 20 - 5
ZGR02004 J978W-3
8W-20 CHARGING SYSTEM
DESCRIPTION AND OPERATION
CHARGING SYSTEM
The chargi ng system i s an i ntegral part of the bat-
tery and starti ng systems. Because al l these systems
work i n conjuncti on, di agnose and test them together.
Ci rcui t A11 connects to the generator output termi -
nal and the Power Di stri buti on Center (PDC). Ci rcui t
A0 connects the battery to the PDC. Ci rcui t Z0 pro-
vi des ground for the generator.
When the i gni ti on swi tch i s i n ei ther the START or
RUN posi ti ons, i t connects ci rcui t A1 from fuse 8 i n
the PDC to ci rcui t A21. Ci rcui t A21 powers ci rcui t
F99 through fuse 18 i n the PDC. Ci rcui t F99 spl i ces
to suppl y current to the coi l si de of the Automati c
Shut Down (ASD) rel ay. The Powertrai n Control
Modul e (PCM) provi des ground for the rel ay on ci r-
cui t K900. Ci rcui t K900 connects to cavi ty C3 of the
PCM.
When the PCM grounds the ASD rel ay, contacts
i nsi de the rel ay cl ose and connect ci rcui t F5 from the
fuse 20 i n the PDC to ci rcui t A142. Ci rcui t A142
spl i ces to suppl y system vol tage to cavi ty C12 of the
PCM. Ci rcui t K72 from Cavi ty C25 of the PCM sup-
pl i es current to the generator fi el d termi nal ..
The PCM has an i nternal vol tage regul ator that
control s generator output. The PCM control s the gen-
erator fi el d on ci rcui t K20. Ci rcui t K20 connects to
PCM cavi ty B10.
When the engi ne operates and there i s current i n
the generator fi el d, the generator produces a B+ vol t-
age. The generator suppl i es B+ vol tage to the battery
through the A11 and A0 ci rcui ts.
HELPFUL INFORMATION
Ci rcui t A21 passes through the juncti on bl ock
before reachi ng fuse 18 i n the PDC.
The ASD rel ay suppl i es battery vol tage for the
fuel i njectors, i gni ti on coi l , and the heated oxygen
sensors.
CHARGING SYSTEM (DIESEL)
The chargi ng system i s an i ntegral part of the bat-
tery and starti ng systems. Because al l these systems
work i n conjuncti on, di agnose and test them together.
Ci rcui t A11 connects to the generator output termi -
nal and the Power Di stri buti on Center (PDC). Ci rcui t
A0 connects the battery to the PDC. The generator i s
case grounded.
Power for the fi el d termi nal i n the generator i s
suppl i ed on ci rcui t A142. Thi s ci rcui t i s HOT when
the contacts i n the Automati c Shut Down (ASD) rel ay
are CLOSED.
The PCM has an i nternal vol tage regul ator that
control s generator output. The PCM control s the gen-
erator fi el d on ci rcui t K20.
When the engi ne operates and there i s current i n
the generator fi el d, the generator produces a B+ vol t-
age. The generator suppl i es B+ vol tage to the battery
through the A11 and A0 ci rcui ts.
HELPFUL INFORMATION
Check the 175 amp fuse i n the PDC
Check the 25 amp fuse l ocated i n cavi ty F20 of
the PDC
8W - 20 - 6 8W - 20 CHARGING SYSTEM ZG
8W-21 STARTING SYSTEM
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . 8W-21-3
Engi ne Starter Motor . . . . . . . . . . . . . . . 8W-21-3, 4
Engi ne Starter Motor Rel ay . . . . . . . . . . 8W-21-3, 4
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-3
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . 8W-21-2, 4
Component Page
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . 8W-21-4
Power Di stri buti on Center . . . . . . . . . 8W-21-2, 3, 4
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-21-4
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-3
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 4
ZG 8W - 21 STARTING SYSTEM 8W - 21 - 1
8
FUSE
40A
7
14
CENTER
DISTRIBUTION
POWER
A0
6
RD
A0
6
RD
C
(8W-21-3)
TO
MOTOR
STARTER
ENGINE
A1
12
RD/WT
B
(8W-21-3)
ENGINE
STARTER
MOTOR
RELAY
TO
A1
12
RD/WT
A1
12
RD/WT
S210
E1 C233
3
0 2
1
1
7
3 ACC
0 OFF
2 RUN
1 START
SWITCH
IGNITION
A41
14
YL
A
(8W-21-3)
TO
SWITCH
INTERLOCK
CLUTCH
A1
12
RD/WT
(8W-10-7)
(8W-10-3)
(8W-10-7)
(8W-10-7)
8W - 21 - 2 8W-21 STARTING SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR02102
1 2
M
C10 C7
C6 C8
C
(8W-21-2)
A0
6
RD
FROM
CENTER
DISTRIBUTION
POWER
T40
14
LG/BK
T40
12
LG/BK
T40
12
LG/BK
1 C917
6 C144
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
Z4
20
BK
Z4
10
BK
G107
S124
B
(8W-21-2)
A1
12
RD/WT
ENGINE
STARTER
MOTOR
1 ROLL-IN
2 HOLD-IN
A
(8W-21-2)
IGNITION
SWITCH
FROM
A41
14
YL
2
1
T141
14
YL/RD
E4 C233
T141
14
YL/RD
CLUTCH
INTERLOCK
SWITCH
FROM
CENTER
DISTRIBUTION
POWER
(8W-15-8)
(8W-15-8)
ZG-RHD 8W-21 STARTING SYSTEM
DIESEL ENGINE
8W - 21 - 3
ZGR02101 J978W-3
C10 C7
C6 C8
T40
12
LG/BK
6 C144
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
1
E4 C233
MOTOR
STARTER
ENGINE
LG/BK
12
T40
2
T41
20
BK/WT
40A
FUSE
8
7
14
A1
12
RD/WT
A0
6
RD
CENTER
DISTRIBUTION
POWER
1 2
A0
6
RD
BATTERY
1 PULL-IN
2 HOLD-IN
A1
12
RD/WT
C233 E1
RD/WT
12
A1
7
T141
14
YL/RD
1 2
SWITCH
POSITION
NEUTRAL
PARK/
T41
20
BK/WT
C132 4
BK/WT
20
T41
POWERTRAIN
CONTROL
MODULE
BK/WT
18
T41
A6
PARK
NEUTRAL
POSITION
SWITCH
SENSE
S134
3
0 2
1
3 ACC
0 OFF
2 RUN
1 START
SWITCH
IGNITION
S210
A41
14
YL
M
C1
(8W-10-7)
(8W-10-3)
(8W-44-7)
(8W-30-10)
(8W-10-7)
(8W-10-7)
8W - 21 - 4 8W-21 STARTING SYSTEM
GAS ENGINES
ZG-RHD
J978W-3 ZGR02103
8W-21 STARTING SYSTEM
DESCRIPTION AND OPERATION
STARTING SYSTEM
Ci rcui t A0 from the battery i s doubl e cri mped at
the posi ti ve battery post. One branch of ci rcui t A0
(battery posi ti ve cabl e) connects to the engi ne starter
motor. The other A0 branch suppl i es vol tage to the
Power Di stri buti on Center (PDC).
Ci rcui t A1 from fuse 8 i n the PDC suppl i es battery
vol tage to the contact si de of the engi ne starter
motor rel ay. When the coi l si de of the engi ne starter
motor rel ay energi zes, the contacts cl ose and connect
ci rcui t A1 to ci rcui t T40. Ci rcui t T40 suppl i es battery
vol tage to the starter motor sol enoi d.
The i gni ti on swi tch suppl i es battery vol tage to the
coi l si de of the starter motor rel ay on ci rcui t A41
when the key i s moved to the START posi ti on and
the PARK/NEUTRAL posi ti on swi tch i s cl osed.
Ground for the coi l si de of the starter motor rel ay i s
suppl i ed by the case grounded PARK/NEUTRAL
posi ti on swi tch. Ci rcui t T41 connects the coi l si de of
the rel ay to the PARK/NEUTRAL posi ti on swi tch.
When the starter motor rel ay energi zes and the
contacts cl ose, ci rcui t T40 suppl i es battery vol tage to
the starter motor sol enoi d. Ci rcui t A0 from the bat-
tery suppl i es vol tage to the starter motor when the
sol enoi d energi zes.
STARTING SYSTEM (DIESEL)
Power for the coi l si de of the engi ne starter motor
rel ay i s suppl i ed on ci rcui t T141. Thi s ci rcui t i s HOT
when the operator has moved the i gni ti on key to the
START posi ti on and the cl utch pedal posi ti on swi tch
i s CLOSED.
Ground for the coi l si de of the rel ay i s suppl i ed on
ci rcui t Z4.
When the coi l si de of the rel ay energi zes the con-
tacts i n the rel ay CLOSE connecti ng ci rcui ts A1 and
T40. The A1 ci rcui t i s protected by a 40 amp fuse
l ocated i n the Power Di stri buti on Center (PDC). Ci r-
cui t T40 connects from the rel ay to the sol enoi d i n
the engi ne starter motor.
Power for the motor i n the starter i s suppl i ed on
ci rcui t A0. Thi s i s a di rect feed from the battery.
Ground for the engi ne starter motor i s suppl i ed
through a case ground.
HELPFUL INFORMATION (DIESEL)
Check the 40 amp fuse l ocated i n the PDC
Check the cl utch pedal posi ti on swi tch for proper
operati on
Check the case ground of the engi ne starter
motor
ZG 8W - 21 STARTING SYSTEM 8W - 21 - 5
8W-30 FUEL/IGNITION SYSTEMS
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Component Page
A/C Compressor Cl utch Rel ay Gas Engi nes . . . . . . . . . . 8W-30-6
A/C Low Pressure Swi tch Gas Engi nes . . . . . . . . . . . . . 8W-30-6
A/C Low Pressure Swi tch Di esel Engi ne . . . . . . . . . . . 8W-30-22
Ai rbag Control Modul e Di esel Engi ne . . . . . . . . . . . 8W-30-31, 32
Ai rbag Control Modul e Gas Engi nes . . . . . . . . . . . . 8W-30-18, 19
Automati c Shut Down Rel ay 4.0L Engi ne . . . . . . . . . 8W-30-14, 15
Automati c Shut Down Rel ay 5.2L Engi ne . . . . . . 8W-30-11, 12, 13
Automati c Shut Down Rel ay Di esel Engi ne . . . . . . . . . . 8W-30-27
Automati c Shut Down Rel ay Gas Engi nes . . . . . . . . . . . 8W-30-5
Automati c Temperature Control Modul e Di esel Engi ne . 8W-30-31, 32
Automati c Temperature Control Modul e Gas Engi nes . 8W-30-18, 19
Battery Temperature Sensor Gas Engi nes . . . . . . . . . . 8W-30-16
Body Control Modul e Di esel Engi ne . . . . . . . . . . . . 8W-30-31, 32
Body Control Modul e Gas Engi nes . . . . . . . . . . . . . 8W-30-18, 19
Camshaft Posi ti on Sensor Gas Engi nes . . . . . . . . . . . . . 8W-30-7
Cl ockspri ng Gas Engi nes . . . . . . . . . . . . . . . . . . . . 8W-30-17
Control l er Anti -Lock Brake Di esel Engi ne . . . . . . . . . . 8W-30-30
Control l er Anti -Lock Brake Gas Engi nes . . . . . . . . . . . . 8W-30-2
Cool ant Level Sensor Di esel Engi ne . . . . . . . . . . . . . . 8W-30-29
Crankshaft Posi ti on Sensor Di esel Engi ne . . . . . . . . . . 8W-30-24
Crankshaft Posi ti on Sensor Gas Engi nes . . . . . . . . . . . . 8W-30-7
Data Li nk Connector Di esel Engi ne . . . . . . . . . . 8W-30-30, 31, 32
Data Li nk Connector Gas Engi nes . . . . . . . . . . . 8W-30-2, 18, 19
Downstream Heated Oxygen Sensor 4.0L Engi ne . . . . . . 8W-30-14
Downstream Heated Oxygen Sensor 5.2L Engi ne . . . . . . 8W-30-13
Dri ver Door Modul e Di esel Engi ne . . . . . . . . . . . . . 8W-30-31, 32
Dri ver Door Modul e Gas Engi nes . . . . . . . . . . . . . 8W-30-18, 19
Duty Cycl e Evap/Purge Sol enoi d Gas Engi nes . . . . . . . . . 8W-30-4
EGR Sol enoi d Di esel Engi ne . . . . . . . . . . . . . . . . . . 8W-30-28
Engi ne Cool ant Temperature Sensor 4.0L Engi ne . . . . . . . 8W-30-9
Engi ne Cool ant Temperature Sensor 5.2L Engi ne . . . . . . . 8W-30-8
Engi ne Cool ant Temperature Sensor Di esel Engi ne . . . . . 8W-30-29
Evaporati ve System Leak Detecti on Pump Gas Engi nes . . . 8W-30-4
Fuel Heater Di esel Engi ne . . . . . . . . . . . . . . . . . . . 8W-30-28
Fuel Heater Rel ay Di esel Engi ne . . . . . . . . . . . . . . . . 8W-30-27
Fuel I njector No. 1 4.0L Engi ne . . . . . . . . . . . . . . . . 8W-30-15
Fuel I njector No. 1 5.2L Engi ne . . . . . . . . . . . . . . . . . 8W-30-11
Fuel I njector No. 2 4.0L Engi ne . . . . . . . . . . . . . . . . 8W-30-15
Fuel I njector No. 2 5.2L Engi ne . . . . . . . . . . . . . . . . 8W-30-12
Fuel I njector No. 3 4.0L Engi ne . . . . . . . . . . . . . . . . 8W-30-15
Fuel I njector No. 3 5.2L Engi ne . . . . . . . . . . . . . . . . . 8W-30-11
Fuel I njector No. 4 4.0L Engi ne . . . . . . . . . . . . . . . . 8W-30-15
Fuel I njector No. 4 5.2L Engi ne . . . . . . . . . . . . . . . . 8W-30-12
Fuel I njector No. 5 4.0L Engi ne . . . . . . . . . . . . . . . . 8W-30-15
Fuel I njector No. 5 5.2L Engi ne . . . . . . . . . . . . . . . . . 8W-30-11
Fuel I njector No. 6 4.0L Engi ne . . . . . . . . . . . . . . . . 8W-30-15
Fuel I njector No. 6 5.2L Engi ne . . . . . . . . . . . . . . . . 8W-30-12
Fuel I njector No. 7 5.2L Engi ne . . . . . . . . . . . . . . . . . 8W-30-11
Fuel I njector No. 8 5.2L Engi ne . . . . . . . . . . . . . . . . 8W-30-12
Fuel Pump Modul e Di esel Engi ne . . . . . . . . . . . . . 8W-30-25, 26
Fuel Pump Modul e Gas Engi nes . . . . . . . . . . . . . . . . 8W-30-16
Fuel Pump Rel ay Gas Engi nes . . . . . . . . . . . . . . . . . 8W-30-16
Fuel Sender Uni t Di esel Engi ne . . . . . . . . . . . . . . . . 8W-30-28
Fuse 4 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . . 8W-30-27
Fuse 7 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . . 8W-30-30
Fuse 7 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Fuse 16 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . 8W-30-22
Fuse 16 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16
Fuse 17 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuse 18 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . 8W-30-22, 27
Fuse 18 Gas Engi nes . . . . . . . . . . . . . . . . . . . . 8W-30-4, 5, 16
Fuse 20 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . 8W-30-27
Fuse 20 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 5
Component Page
Generator Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Generator Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . 8W-30-23
Gl ow Pl ug Di esel Engi ne . . . . . . . . . . . . . . . . . . . . 8W-30-26
Gl ow Pl ug Rel ay Di esel Engi ne . . . . . . . . . . . . . . . . . 8W-30-26
I dl e Ai r Control Motor 4.0L Engi ne . . . . . . . . . . . . . . 8W-30-21
I dl e Ai r Control Motor 5.2L Engi ne . . . . . . . . . . . . . . 8W-30-20
I gni ti on Coi l Gas Engi nes . . . . . . . . . . . . . . . . . . . . . 8W-30-5
I nstrument Cl uster Di esel Engi ne . . . . . . . . . . . . . 8W-30-31, 32
I nstrument Cl uster Gas Engi nes . . . . . . . . . . . . . . 8W-30-18, 19
I ntake Ai r Temperature Sensor 4.0L Engi ne . . . . . . . . . . 8W-30-9
I ntake Ai r Temperature Sensor 5.2L Engi ne . . . . . . . . . . 8W-30-8
Juncti on Bl ock Di esel Engi ne . . . . . . . . . . . . . . . . . . 8W-30-30
Juncti on Bl ock Gas Engi nes . . . . . . . . . . . . . . . . . . . 8W-30-2
Left Swi tch Gas Engi nes . . . . . . . . . . . . . . . . . . . . . 8W-30-17
Mani fol d Absol ute Pressure Sensor 4.0L Engi ne . . . . . . . . 8W-30-9
Mani fol d Absol ute Pressure Sensor 5.2L Engi ne . . . . . . . . 8W-30-8
Mani fol d Absol ute Pressure Sensor Gas Engi nes . . . . . . . 8W-30-7
Mass Ai r Fl ow Modul e Di esel Engi ne . . . . . . . . . . . . . 8W-30-26
Memory Seat Modul e Di esel Engi ne . . . . . . . . . . . . 8W-30-31, 32
Memory Seat Modul e Gas Engi nes . . . . . . . . . . . . . 8W-30-18, 19
MSA Control l er Di esel Engi ne . . 8W-30-22, 23, 24, 25, 26, 27, 29, 30
Needl e Sensor Di esel Engi ne . . . . . . . . . . . . . . . . . . 8W-30-24
Oi l Pressure Sensor Di esel Engi ne . . . . . . . . . . . . . . . 8W-30-29
Oi l Pressure Sensor Gas Engi nes . . . . . . . . . . . . . . . . 8W-30-10
Output Shaft Speed Sensor Gas Engi nes . . . . . . . . . . . 8W-30-10
Overdri ve Pressure Swi tch Gas Engi nes . . . . . . . . . . . . 8W-30-4
Overhead Consol e Di esel Engi ne . . . . . . . . . . . . . . 8W-30-31, 32
Overhead Consol e Gas Engi nes . . . . . . . . . . . . . . 8W-30-18, 19
Park/Neutral Posi ti on Swi tch Gas Engi nes . . . . . . . . . . 8W-30-10
Passenger Door Modul e Di esel Engi ne . . . . . . . . . . 8W-30-31, 32
Passenger Door Modul e Gas Engi nes . . . . . . . . . . . 8W-30-18, 19
Pedal Posi ti on Sensor Di esel Engi ne . . . . . . . . . . . . . . 8W-30-23
Power Di stri buti on Center 4.0L Engi ne . . . . . . . . . . 8W-30-14, 15
Power Di stri buti on Center 5.2L Engi ne . . . . . . . . 8W-30-11, 12, 13
Power Di stri buti on Center Di esel Engi ne . . . . . . . . . 8W-30-22, 27
Power Di stri buti on Center Gas Engi nes . . . . . . . 8W-30-3, 4, 5, 16
Powertrai n Control Modul e 4.0L Engi ne . . . . . . 8W-30-9, 14, 15, 21
Powertrai n Control Modul e 5.2L Engi ne . . . 8W-30-8, 11, 12, 13, 20
Powertrai n Control Modul e Di esel Engi ne . 8W-30-22, 23, 24, 27, 28, 29,
30, 31, 32
Powertrai n Control Modul e Gas Engi nes . 8W-30-2, 3, 4, 5, 6, 7, 10, 16,
17, 18, 19
Radi o Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . 8W-30-31, 32
Radi o Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . 8W-30-18, 19
Ri ght Swi tch Gas Engi nes . . . . . . . . . . . . . . . . . . . . 8W-30-17
Speed Proporti onal Steeri ng Modul e Gas Engi nes . . . . . . . 8W-30-2
Stop Lamp Swi tch Gas Engi nes . . . . . . . . . . . . . . . . 8W-30-10
Stop Lamp Swi tch Di esel Engi ne . . . . . . . . . . . . . . . . 8W-30-29
Throttl e Posi ti on Sensor 4.0L Engi ne . . . . . . . . . . . . . . 8W-30-9
Throttl e Posi ti on Sensor 5.2L Engi ne . . . . . . . . . . . . . . 8W-30-8
Throttl e Posi ti on Sensor Gas Engi nes . . . . . . . . . . . . . . 8W-30-7
Transmi ssi on Control Rel ay Gas Engi nes . . . . . . . . . . . . 8W-30-3
Transmi ssi on Sol enoi d Assembl y Gas Engi nes . . . . . . . 8W-30-3, 6
Upstream Heated Oxygen Sensor 4.0L Engi ne . . . . . . . . 8W-30-14
Upstream Heated Oxygen Sensor 5.2L Engi ne . . . . . . . . 8W-30-13
Vehi cl e I nformati on Center Di esel Engi ne . . . . . . . . 8W-30-31, 32
Vehi cl e I nformati on Center Gas Engi nes . . . . . . . . . 8W-30-18, 19
Vehi cl e Speed Control Servo Gas Engi nes . . . . . . . . . 8W-30-4, 10
Vehi cl e Speed Control /Horn Swi tch Gas Engi nes . . . . . . . 8W-30-17
Vehi cl e Speed Sensor Di esel Engi ne . . . . . . . . . . . . . . 8W-30-24
Vehi cl e Speed Sensor Gas Engi nes . . . . . . . . . . . . . . . 8W-30-17
Water I n Fuel Sensor Di esel Engi ne . . . . . . . . . . . . . . 8W-30-24
ZG 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 1
7
FUSE
20A
BATT A250
8 C4
JUNCTION
BLOCK
12
16
F75
18
VT
F75
18
VT
S201
7 5 6 4
DATA
LINK
CONNECTOR
13 12 C3 C29 C27 C3
D98
20
WT
D98
20
WT
D83
20
BK/PK
D83
18
BK/PK
D83
20
BK/PK
D83
20
BK/PK
D83
18
BK/PK
MODULE
CONTROL
POWERTRAIN CONTROLLER
ANTI-LOCK
BRAKE
MODULE
STEERING
PROPORTIONAL
SPEED
S200
C1 20
SCI
TRANSMIT
SCI
RECEIVE RECEIVE
SCI
RECEIVE
SCI
TRANSMIT
SCI
4
C235 F14 C234
6
D84
20
BK/WT
D84
18
BK/WT
F15 C234
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z1
18
BK
Z1
18
BK
Z1
18
BK
2 1 C132
C236
G103
H11 H12
(8W-65-2)
(8W-35-2)
(8W-12-8)
(8W-12-2)
(8W-10-10)
(8W-12-8)
8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
ZG-RHD
J978W-3 ZGR03001
3
GENERATOR
B10 C2
K20
18
DG
K20
18
DG
K20
18
DG
6 C132
2 C144
DRIVER
FIELD
GENERATOR
17
FUSE
15A
A13
BATT A0
A14
A7 A10
A8 A6
F92
18
LG
TRANSMISSION
CONTROL
RELAY
2
GENERATOR
K72
18
DG/VT
K72
18
DG/VT
3 C144
C25
C3
GENERATOR
FIELD
SOURCE
K72
18
DG/VT
T20
18
LB
T20
18
LB
1 C131
6
1
TRANSMISSION
SOLENOID
ASSEMBLY
5 7
B21 B8 B11
T60
18
BR
T59
18
PK
T22
18
DG/LB
C2 C2 C2
TORQUE
CONVERTER
CLUTCH
SOLENOID
CONTROL
CONTROL
SOLENOID
FORCE
VARIABLE O/D
CONTROL
RELAY
TRANSMISSION
C2 B30
T66
20
BR/OR
T66
20
BR/OR
7 C132
CENTER
DISTRIBUTION
POWER
CENTER
DISTRIBUTION
POWER
MODULE
CONTROL
POWERTRAIN
POWERTRAIN
CONTROL
MODULE
SOLENOID
CONTROL
TORQUE
CLUTCH
CONVERTER
SOLENOID
FORCE
SOLENOID
VARIABLE
SOLENOID
CONTROL
O/D
G104
BK/TN
14
BK/TN
14
Z12
GROUND
A31
C1
Z12
GROUND
A32
C1
DRIVER
FIELD
GENERATOR
SOURCE
FIELD
GENERATOR
(8W-10-3)
(8W-10-3)
(8W-10-3)
(8W-20-3)
(8W-10-14)
(8W-20-3)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
8W - 30 - 3
ZGR03002 J978W-3
20
FUSE
20A
A20
A19 A16
A15
15A
FUSE
18
BATT A0 ST-RUN A21
F5
14
RD/YL
CENTER
DISTRIBUTION
POWER
F5
14
RD/YL
S100
F5
14
RD/YL
C131
C1 A22
FUSED
B (+)
MODULE
CONTROL
POWERTRAIN
2
3 4
EVAPORATIVE
SYSTEM
LEAK
DETECTION
PUMP
S101
F99
18
OR
F99
20
OR
F99
20
OR
F99
20
OR
F99
18
OR
1
2
DUTY
CYCLE
EVAP/
PURGE
SOLENOID
J95
18
DG/RD
J96
18
VT/RD
K52
18
PK/BK
2 C131
A2 C1 C3 C10 C14 C3 C3 C20
FUSED
IGN.
(ST-RUN) DRIVER
SOLENOID
VAPOR CANISTER
CANISTER
SWITCH PUMP
DRIVE
VAPOR DUTY
PURGE
EVAP/
CYCLE
5
C13
C3
OVERDRIVE
SWITCH
6
20
OR
T9
SENSE
SWITCH
OFF
OVERDRIVE
18
T9
OR
F20 C234
BR/YL
20
G68
OVERDRIVE
OFF
C235
G68
BR/YL
18
9
DRIVER
LAMP
C6
C3
7
VEHICLE
SPEED
CONTROL
SERVO
1 2
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL
SPEED
CONTROL
VENT
SOLENOID
CONTROL
TN/RD
V36
18
SOLENOID
CONTROL
C4
C3
VACUUM
SPEED CONTROL
LG/RD
V35
18
C3
SOLENOID
CONTROL
C5
SPEED
CONTROL VENT
CONTROL
SOLENOID
PRESSURE
(8W-33-2)
(8W-31-5)
(8W-10-15) (8W-10-16)
(8W-10-3)
(8W-10-8) (8W-10-3)
(8W-10-14) (8W-10-16)
8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
ZG-RHD
J978W-3 ZGR03003
20
FUSE
20A
A20
A19 A16
A15
15A
FUSE
18
BATT A0 ST-RUN A21
B20 B17
B16 B18
F99
18
OR
F99
20
OR
F5
14
RD/YL
S101
C3 C3
DOWN
SHUT
AUTOMATIC
K900
18
PK/WT
MODULE
CONTROL
POWERTRAIN
ASD
RELAY
CONTROL OUTPUT
RELAY
ASD
C12 C3
CENTER
DISTRIBUTION
POWER
F5
18
RD/YL
S100
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
4 C131
1
2
IGNITION
COIL
A7 C1
K19
18
GY/WT
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
S128 S129
4.0L 5.2L
DRIVER
NO. 1
COIL
IGNITION
RELAY
(IN PDC)
(8W-70-7) (8W-70-7)
(8W-10-16)
(8W-10-3)
(8W-10-15)
(8W-10-8) (8W-10-3)
(8W-10-14) (8W-10-16)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
8W - 30 - 5
ZGR03004 J978W-3
B31
4
2
TRANSMISSION
SOLENOID
ASSEMBLY
3 8
B29 A4 B1
T25
18
LG
K4
18
BK/LB
T54
18
VT
C2 C1 C2
TRANSMISSION
TEMPERATURE
SENSOR
SIGNAL
GROUND
SENSOR GOVERNOR
PRESSURE
SIGNAL
S135
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
S127
K6
18
VT/WT
K6
18
VT/WT
S132
4.0L 5.2L
5V
SUPPLY
C2
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
POWERTRAIN
A/C
LOW
PRESSURE
SWITCH
18
DB/BK
1
PRESSURE
SWITCH
C3
A/C
CONTROL
COMPRESSOR
C3
RELAY
DB/RD
CLUTCH
C1
A/C
C13
18
C3 C22
B5
A/C
CLUTCH
RELAY
COMPRESSOR
(IN PDC)
(8W-31-3)
(8W-42-10)
(8W-42-12)
(8W-70-2)
(8W-70-2)
(8W-70-3)
8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
ZG-RHD
J978W-3 ZGR03005
C1
A17
3
1
2
CAMSHAFT
POSITION
SENSOR
SIGNAL
SENSOR
GROUND
5V
SUPPLY SUPPLY
5V
GROUND
SENSOR
SIGNAL
SENSOR
POSITION
CRANKSHAFT
3
1
2
5V
SUPPLY
K25
18
WT/BK
K25
20
WT/BK
K25
20
WT/BK
SIGNAL
SENSOR
POSITION
CAMSHAFT
A18
CAMSHAFT
POSITION
SENSOR SENSOR
POSITION
CRANKSHAFT
A4
SENSOR
GROUND
SIGNAL
SENSOR
POSITION
CRANKSHAFT
A8
K24
18
GY/BK
K4
20
BK/LB
K4
20
BK/LB
K27
18
RD/LG
K4
18
BK/LB
C1 C1 C1
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
POWERTRAIN THROTTLE
POSITION
SENSOR
WT/BK
20
K25
**1
S133
3
K25
20
WT/BK
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
S136
4.0L 4.0L 5.2L 5.2L
S135
S135
K4
18
BK/LB
*3
(8W-70-3)
(8W-70-3)
(8W-70-4)
(8W-30-8)
(8W-30-9)
(8W-30-8)
(8W-30-9)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
8W - 30 - 7
ZGR03006 J978W-3
C1
A17
5V
SUPPLY
K25
18
WT/BK
K25
20
WT/BK
K25
20
WT/BK
S133
SIGNAL
SENSOR
ECT
A16 A15
SIGNAL
TPS
A23 C1 C1 C1 C1 A27
MAP
SENSOR
SIGNAL
K4
20
BK/LB
K4
20
BK/LB
C1 A4
SENSOR
GROUND
S136
K4
16
BK/LB
K4
18
BK/LB
K4
16
BK/LB
K2
16
TN/BK
K4
18
BK/LB
K21
16
BK/RD
S135
K70
18
RD/WT
K22
18
OR/DB
1
2
1
2
SENSOR
TEMPERATURE
COOLANT
ENGINE INTAKE
AIR
TEMPERATURE
SENSOR
2 3
1
1 2
3
SIGNAL
SENSOR
IAT
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD THROTTLE
POSITION
SENSOR
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
POWERTRAIN
(8W-30-7)
(8W-70-4)
(8W-70-3)
8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM
5.2L ENGINE
ZG-RHD
J978W-3 ZGR03007
C1
A17
5V
SUPPLY
K25
18
WT/BK
K25
20
WT/BK
K25
20
WT/BK
S133
SIGNAL
SENSOR
ECT
A16 A15
SIGNAL
TPS
A23 C1 C1 C1 C1 A27
MAP
SENSOR
SIGNAL
K4
20
BK/LB
K4
20
BK/LB
C1 A4
SENSOR
GROUND
S127
K4
16
BK/LB
K4
18
BK/LB
K4
16
BK/LB
K2
16
TN/BK
K4
18
BK/LB
K21
16
BK/RD
S135
K70
18
RD/WT
K22
18
OR/DB
1
2
1
2
SENSOR
TEMPERATURE
COOLANT
ENGINE INTAKE
AIR
TEMPERATURE
SENSOR
2 1
3
1 2
3
SIGNAL
SENSOR
IAT
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD THROTTLE
POSITION
SENSOR
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
POWERTRAIN
(8W-30-7)
(8W-70-2)
(8W-70-3)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
4.0L ENGINE
8W - 30 - 9
ZGR03008 J978W-3
C2
B28
MODULE
CONTROL
POWERTRAIN
OUTPUT
SHAFT
SPEED
SENSOR
SIGNAL
(+) (-)
SIGNAL
SENSOR
SPEED
SHAFT
OUTPUT
B25
C2 C2
B23
OIL
PRESSURE
SENSOR
SIGNAL GROUND
SENSOR
A4
C1 C1
A6
PARK/
NEUTRAL
POSITION
SWITCH
SENSE
1
2
1
2
SENSOR
SPEED
SHAFT
OUTPUT
OIL
PRESSURE
SENSOR
SWITCH
POSITION
NEUTRAL
PARK/
T14
18
LG/WT
T13
18
DB/BK
G6
18
GY/WT
K4
18
BK/LB
K4
20
BK/LB
T41
18
BK/WT
T41
20
BK/WT
S135 S134
2
L53
L53
L53
SENSE
SWITCH
LAMP
STOP
1
F13
C24
S206
BR
20
20
BR
C3
18
BR
Z1
BK
14
2
BK
14
Z1
BK
2
20
Z1
G304
C301
S202
SWITCH
LAMP
STOP
SPEED
CONTROL
ON/OFF
SWITCH
SENSE
C234
YL/RD
18
V32
3
C3
C11
F9
V32
20
YL/RD
SERVO
CONTROL
SPEED
VEHICLE
OUTPUT
SWITCH
ON/OFF
CONTROL
SPEED
DB/LG
3
V30
20
2
8
DB/LG
C235
20
V30
4
(8W-33-2)
(8W-33-2)
(8W-15-18)
(8W-15-18)
(8W-31-5) (8W-21-4) (8W-70-3)
(8W-44-7)
8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
ZG-RHD
J978W-3 ZGR03009
A142
18
DG/OR
A142
18
DG/OR
A142
18
DG/OR
4 C131
A142
18
DG/OR
FUEL
INJECTOR
NO. 1
DRIVER
B4 C2 B5 C2 B2 C2
S128
A142
18
DG/OR
A142
18
DG/OR
2
1
2
1
2
1
DRIVER
NO. 3
INJECTOR
FUEL FUEL
INJECTOR
NO. 7
DRIVER
K11
18
WT/DB
K13
18
YL/WT
K17
18
DB/WT GY
18
K38
DRIVER
NO. 5
INJECTOR
FUEL
1
2
DG/OR
18
A142
C2 B6
NO. 1
INJECTOR
FUEL FUEL
INJECTOR
NO. 3
FUEL
INJECTOR
NO. 7
FUEL
INJECTOR
NO. 5
SHUT
AUTOMATIC
B16
B17
BATT F5
S129
MODULE
CONTROL
POWERTRAIN
CENTER
DISTRIBUTION
POWER
DOWN
RELAY
(8W-70-7)
(8W-10-16)
(8W-70-7)
(8W-10-3)
(8W-20-5)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
5.2L ENGINE
8W - 30 - 11
ZGR03010 J978W-3
A142
18
DG/OR
A142
18
DG/OR
4 C131
A142
18
DG/OR
FUEL
INJECTOR
NO. 2
DRIVER
B15 C2 B16 C2 B13 C2
A142
18
DG/OR
A142
18
DG/OR
2
1
2
1
2
1
DRIVER
NO. 4
INJECTOR
FUEL FUEL
INJECTOR
NO. 8
DRIVER
K12
18
TN
K14
18
LB/BR
K18
18
DB/YL BR/YL
18
K58
DRIVER
NO. 6
INJECTOR
FUEL
1
2
DG/OR
18
A142
C2 B12
NO. 2
INJECTOR
FUEL FUEL
INJECTOR
NO. 4
FUEL
INJECTOR
NO. 8
FUEL
INJECTOR
NO. 6
SHUT
AUTOMATIC
B16
B17
BATT F5
S128
MODULE
CONTROL
POWERTRAIN
CENTER
DISTRIBUTION
POWER
DOWN
RELAY
(8W-10-16)
(8W-70-7)
(8W-10-3)
(8W-20-5)
8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM
5.2L ENGINE
ZG-RHD
J978W-3 ZGR03011
A142
18
DG/OR
A142
18
DG/OR
4 C131
A24 C1
A4 C1
A25 C1
A142
18
DG/OR
A142
18
DG/OR
SHUT
AUTOMATIC
B16
B17
BATT F5
S129
MODULE
CONTROL
POWERTRAIN
4
3 2
1 1
2 3
4
G105
Z12
16
BK/TN
Z12
18
BK/TN
Z12
18
BK/TN
S130
SENSOR
OXYGEN
HEATED
UPSTREAM
SENSOR
OXYGEN
HEATED
DOWNSTREAM
DOWNSTREAM
HEATED
OXYGEN
SENSOR
SIGNAL
K141
18
BK/PK K41
18
BK/OR
K4
18
BK/LB
K4
18
BK/LB
S135
K4
18
BK/LB
SENSOR
GROUND
SIGNAL
SENSOR
OXYGEN
HEATED
UPSTREAM
S128
A142
18
DG/OR
CENTER
DISTRIBUTION
POWER
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
POWERTRAIN
DOWN
RELAY
(8W-10-16)
(8W-70-7)
(8W-15-7)
(8W-15-7)
(8W-70-3)
(8W-70-7)
(8W-10-3)
(8W-20-5)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
5.2L ENGINE
8W - 30 - 13
ZGR03012 J978W-3
A142
18
DG/OR
A142
18
DG/OR
4 C131
A4 C1
A25 C1
A142
18
DG/OR
A142
18
DG/OR
SHUT
AUTOMATIC
B16
B17
BATT F5
S129
MODULE
CONTROL
POWERTRAIN
4
3 2
1 1
2 3
4
G105
Z12
16
BK/TN
Z12
18
BK/TN
Z12
18
BK/TN
S130
SENSOR
OXYGEN
HEATED
UPSTREAM
SENSOR
OXYGEN
HEATED
DOWNSTREAM
DOWNSTREAM
HEATED
OXYGEN
SENSOR
SIGNAL
K141
18
BK/PK
K41
18
BK/OR
K4
18
BK/LB
K4
18
BK/LB
S135
K4
18
BK/LB
SENSOR
GROUND
SIGNAL
SENSOR
OXYGEN
HEATED
UPSTREAM
S127
K4
18
BK/LB
CENTER
DISTRIBUTION
POWER
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
POWERTRAIN
DOWN
RELAY
C1 A24
(8W-10-16)
(8W-70-7)
(8W-15-7)
(8W-15-7)
(8W-70-3)
(8W-70-2)
(8W-10-3)
(8W-20-5)
8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM
4.0L ENGINE
ZG-RHD
J978W-3 ZGR03013
A142
18
DG/OR
A142
18
DG/OR
4 C131
A142
18
DG/OR
FUEL
INJECTOR
NO 1
DRIVER
B4 C2
A142
18
DG/OR
A142
18
DG/OR
1
2
1
2
2
1
K11
18
WT/DB
K12
18
TN
K14
18
LB/BR
YL/WT
18
K13
DRIVER
NO 3
INJECTOR
FUEL
1
2
DG/OR
18
A142
C2 B5
NO. 1
INJECTOR
FUEL
FUEL
INJECTOR
NO. 2
FUEL
INJECTOR
NO. 4
FUEL
INJECTOR
NO. 3
SHUT
AUTOMATIC
B16
B17
BATT F5
MODULE
CONTROL
POWERTRAIN
S128
NO. 5
INJECTOR
FUEL
NO. 6
INJECTOR
FUEL
A142
18
DG/OR
2
1
K38
18
GY
BR/YL
18
K58
2
1
DG/OR
18
A142
B6 C2
FUEL
INJECTOR
NO 5
DRIVER
FUEL
INJECTOR
NO. 6
DRIVER DRIVER
NO. 4
INJECTOR
FUEL
POWERTRAIN
CONTROL
MODULE
DRIVER
NO. 2
INJECTOR
FUEL
C2 B15 B16 C2 C2 B12
S129
A142
18
DG/OR
CENTER
DISTRIBUTION
POWER
DOWN
RELAY
(8W-10-16)
(8W-70-7)
(8W-70-7)
(8W-10-3)
(8W-20-5)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
4.0L ENGINE
8W - 30 - 15
ZGR03014 J978W-3
16
FUSE
20A
A11
A12 A16
A15
15A
FUSE
18
BATT A0 ST-RUN A21
C20 C17
C16 C18
F99
18
OR
F99
20
OR
A61
16
DG/BK
S101
C3 C19
(IN PDC)
RELAY
PUMP
FUEL
K81
18
DB
MODULE
CONTROL
POWERTRAIN
1
6 3
4
MODULE
PUMP
FUEL
A64
16
DG/WT
A64
16
DG/WT
18 C304
G305
Z1
16
BK
Z1
12
BK
S304
FUEL
PUMP
RELAY
CONTROL
SENSE
FUEL
LOW
C26 C3
G40
20
LB/BK
G40
18
LB/BK
10 C304
K4
20
BK/LB
K167
20
BR/YL
C304
C3
C15
MODULE
CONTROL
POWERTRAIN
BATTERY
TEMPERATURE
SENSE
SENSOR
TEMPERATURE
BATTERY
2
1
S102
T222
18
RD/YL
K4
18
BK/LB
K4
20
BK/LB
C131
5.2L 4.0L
K4
20
BK/LB
K4
18
BK/LB
C1 A4
SENSOR
GROUND
K4
18
BK/LB
S135
CENTER
DISTRIBUTION
POWER
15 10
M
SIGNAL
(8W-10-14) (8W-10-14)
(8W-10-3) (8W-10-8)
(8W-10-15)
(8W-15-15)
(8W-15-15)
(8W-70-3)
(8W-10-3)
8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
ZG-RHD
J978W-3 ZGR03015
VEHICLE
SPEED
SENSOR
SIGNAL
5 VOLT
SUPPLY SIGNAL
SWITCH
CONTROL
SPEED
POWERTRAIN
CONTROL
MODULE
CLOCKSPRING
1
2 1 3 4 5
LEFT
SWITCH SWITCH
RIGHT
3 COAST
1 ON/OFF
2 SET ACC
VEHICLE
SPEED
CONTROL/
HORN
SWITCH
5 CANCEL
4 RES/ACC
C32
C3 C2
B31
S132
S131
B27
C2
3 1
5 VOLT
SUPPLY
SENSOR
SPEED
VEHICLE
C1
A4
SENSOR
GROUND
2
K6
18
VT/WT
K6
18
VT/WT
G7
18
WT/OR
G7
18
WT/OR
K95
18
PK
F19 C234
K95
20
PK
4.0L 5.2L
BK/LB
18
K4 K4
20
BK/LB
K4
18
BK/LB
F8 C234
S102
BK/LB
20
K4
BK/LB
20
K4
10 C131
BK/LB
18
K4
GROUND
SENSOR
BK/LB
18
K4
2
S135
SIGNAL
SENSOR
VEHICLE
SPEED
(8W-70-3)
(8W-70-6)
(8W-70-2)
(8W-70-2)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
8W - 30 - 17
ZGR03016 J978W-3
11
DATA
LINK
CONNECTOR
18
D2
18
WT/BK
CONSOLE
OVERHEAD
INSTRUMENT
CLUSTER
C1 20
9
5
C11
8
C3 C28
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
VEHICLE
INFORMATION
CENTER
2 C2
RADIO
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
BODY
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
S203
2 C302 2 C231
20
C235
10
19 C1 C1 9 9
S307
AIRBAG
CONTROL
MODULE
MEMORY
SEAT
MODULE
DRIVER
DOOR
MODULE
PASSENGER
DOOR
MODULE
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
20
WT/BK
D2
18
WT/BK
D2
18
WT/BK
4 C329 12 C334 12 C351
C1
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
(8W-60-3)
(8W-61-3)
(8W-62-3)
(8W-60-2)
(8W-61-2)
(8W-62-2)
(8W-63-15) (8W-43-3)
(8W-45-2)
(8W-47-2)
(8W-46-7)
(8W-42-9)
(8W-40-3)
(8W-49-2)
8W - 30 - 18 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
ZG-RHD
J978W-3 ZGR03017
3
DATA
LINK
CONNECTOR
19
D1
18
VT/BR
CONSOLE
OVERHEAD
INSTRUMENT
CLUSTER
C1 19
8
3 C10
7
C3 C30
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
VEHICLE
INFORMATION
CENTER
1 C2
RADIO
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
BODY
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
S204
1 C302 1 C231
19
C235
11
18 C1 C1 8 8
S306
AIRBAG
CONTROL
MODULE
MEMORY
SEAT
MODULE
DRIVER
DOOR
MODULE
PASSENGER
DOOR
MODULE
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
20
VT/BR
D1
18
VT/BR
D1
18
VT/BR
3 C329 13 C334 13 C351
CCD
BUS
(+) (+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD (+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
C1
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
(8W-60-3)
(8W-61-3)
(8W-62-3)
(8W-60-2)
(8W-61-2)
(8W-62-2)
(8W-43-15) (8W-43-3)
(8W-45-2)
(8W-47-2)
(8W-46-7)
(8W-42-9)
(8W-40-3)
(8W-49-2)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
8W - 30 - 19
ZGR03018 J978W-3
C1 A11
2 3 1 4
IDLE
AIR
CONTROL
MOTOR
A19 C1 C1 A20 A10 C1
IAC
MOTOR
NO. 3
DRIVER DRIVER
NO. 2
MOTOR
IAC IAC
MOTOR
NO. 1
DRIVER DRIVER
NO. 4
MOTOR
IAC
MODULE
CONTROL
POWERTRAIN
K40
16
BR/WT
K60
16
YL/BK
K39
16
GY/RD
K59
16
VT/BK
NO. 3
MOTOR
IAC
MOTOR
NO. 2
IAC
NO. 1
MOTOR
IAC
NO. 4
MOTOR
IAC
8W - 30 - 20 8W-30 FUEL/IGNITION SYSTEM
5.2L ENGINE
ZG-RHD
J978W-3 ZGR03019
C1 A11
3 2 4 1
IDLE
AIR
CONTROL
MOTOR
A19 C1 C1 A20 A10 C1
IAC
MOTOR
NO. 3
DRIVER DRIVER
NO. 2
MOTOR
IAC IAC
MOTOR
NO. 1
DRIVER DRIVER
NO. 4
MOTOR
IAC
MODULE
CONTROL
POWERTRAIN
K40
16
BR/WT
K60
16
YL/BK
K39
16
GY/RD
K59
16
VT/BK
NO. 3
MOTOR
IAC
MOTOR
NO. 2
IAC IAC
NO. 1
MOTOR
NO. 4
MOTOR
IAC
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
4.0L ENGINE
8W - 30 - 21
ZGR03020 J978W-3
18
FUSE
15A
A15
ST-RUN A21
A16
CENTER
DISTRIBUTION
POWER
A12
A11
15A
FUSE
16
F99
18
OR
F99
20
OR
F99
20
OR
F99
18
OR
S101
S138
4 C131
BATT A0
C4
11
C4 9 3 C4
F6
18
WT/RD
F6
18
WT/RD
11 C131
MODULE
CONTROL
POWERTRAIN
FUSED
B (+)
FUSED
IGN.
SWITCH
OUTPUT
(ST-RUN)
GROUND GROUND
12
C4
46
GROUND GROUND
(ST-RUN)
OUTPUT
SWITCH
IGN.
FUSED
38
1
F99
20
RD/OR
24
GROUND
S130
Z12
14
BK/TN
Z12
16
BK/TN
Z12
16
BK/TN
Z12
16
BK/TN
Z12
16
BK/TN
G104
CONTROLLER
MSA
Z12
10
BK/TN
37
A/C
SWITCH
SIGNAL
28
A/C
COMPRESSOR
CLUTCH
RELAY
CONTROL
C103
20
DG
C13
16
DB/RD
C13
16
DB/RD
C132
1
59
SIGNAL
SWITCH
A/C
MODULE
CONTROL
POWERTRAIN
SWITCH
PRESSURE
LOW
A/C
(8W-12-20)
(8W-10-8)
(8W-10-3)
(8W-10-13)
(8W-10-15)
(8W-10-15)
(8W-10-3)
(8W-42-13)
8W - 30 - 22 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03021
55
MODULE
CONTROL
POWERTRAIN
PEDAL
POSITION
SENSOR
65
SUPPLY
5V
57
SIGNAL
SENSOR
POSITION
THROTTLE
15 3
1
CONTROLLER
MSA
4 3 2
SENSOR
POSITION
PEDAL 5V
SUPPLY
44
LAMP
START
TO
WAIT COIL
DRIVER
2
OUTPUT
41
FLT
SIGNAL
22
K255
20
WT/DG
K151
20
WT
K6
20
VT/WT
K22
20
OR/DB
PEDAL
POSITION
SENSOR
LOW
IDLE
POSITION
SWITCH
THROTTLE
POSITION
SENSOR
SIGNAL
SWITCH
POSITION
IDLE
LOW
C4 C4 C4
FLT
SIGNAL
27
COIL
DRIVER
2
WAIT
TO
START
LAMP
26
K255
20
WT/DG
K255
20
WT/DG
K151
20
WT
K151
20
WT
K6
20
VT/WT
K6
20
VT/WT
K22
20
OR/DB
K22
20
OR/DB
K92
20
PK
K185
18
OR/LB
K48
18
OR/RD
D12 C307 D11 D10 D9
1 2 3 4 C182
GENERATOR
FIELD
DRIVER
20 C4
3
GENERATOR
K20
18
DG/YL
(8W-20-2)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
8W - 30 - 23
ZGR03022 J978W-3
12 8
CONTROLLER
MSA
43
NEEDLE
MOVEMENT
SENSOR
(+) SIGNAL
SENSOR
SPEED
VEHICLE CRANK
POSITION
SENSOR
SIGNAL
11 33
(+)
SENSOR
MOVEMENT
NEEDLE GROUND
2
1
NEEDLE
SENSOR
2
3
CRANKSHAFT
POSITION
SENSOR
K67
20
BR/BK
K68
20
LG/YL
K24
20
GY/BK
K4
20
BK/LB
SUPPLY
5V
WATER
IN
FUEL
SENSOR SENSOR
SENSOR
SPEED
VEHICLE
23 6 47
MODULE
CONTROL
POWERTRAIN
G7
20
WT/OR
G7
20
WT/OR
S140
CONTROLLER
MSA
2
3
VEHICLE
SPEED
SENSOR
SIGNAL
SUPPLY
5V
1
K7
20
OR/WT
VEHICLE
SPEED
SENSOR
SENSOR
GROUND
4
SENSOR
GROUND
POWERTRAIN
CONTROL
MODULE
K167
20
BR/YL
K167
20
BR/YL
C4
C4 C4 C4
2
1
SENSOR
FUEL
IN
WATER
G123
20
DG/WT
K167
20
BR/YL
S141
G7
20
WT/RD
(DIESEL)
K4
20
BK/LB
S136
C4
SIGNAL
TACH
24
TACH
SIGNAL
2
G21 20 GY/LB
(8W-33-5)
(8W-70-9) (8W-70-8)
8W - 30 - 24 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03023
8
1
29
FUEL
PUMP
MODULE
CONTROLLER
MSA
7
2
52
3
51
5
53
6
63
7
SLEEVE
POSITION
SENSOR
(+) SENSOR
POSITION
SLEEVE
CONT
(-)
SENSOR
POSITION
SLEEVE FUEL
TIMING
SHUT-OFF
SENSOR FEED
SHUT-OFF
SIGNAL
SENSOR
TEMPERATURE
FUEL
SLEEVE
POSITION
SENSOR
(+) SENSOR
POSITION
SLEEVE
CONT SLEEVE
POSITION
SENSOR
(-) SENSOR
SHUT-OFF
TIMING
FUEL SHUT-OFF
FEED
FUEL
TEMPERATURE
SENSOR
SIGNAL
GROUND
K134
20
LB/BK
K57
20
LG/OR
K135
20
WT/BK
K238
16
VT
K153
20
OR
K156
20
GY
S144
K140
14
TN/WT
K140
16
TN/WT
K140
16
TN/WT
K140
16
TN/WT
4 5 49
MSA
CONTROLLER
GROUND GROUND GROUND
68 45 23
16 16
DG/OR
14
A142 A142
DG/OR DG/OR
A142
A142
DG/OR
16 14
DG/OR
A142
10 9
SHUT
DOWN
RELAY
OUTPUT
AUTO AUTO
OUTPUT
RELAY
DOWN
SHUT
RELAY
DOWN
SHUT
AUTO
OUTPUT OUTPUT
AUTO
SHUT
DOWN
RELAY
OUTPUT
AUTO
SHUT
DOWN
RELAY
S128
SENSOR
GROUND
33
GROUND
K4
20
BK/LB
K4
20
BK/LB
S136
4
(8W-70-7) (8W-70-8)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
8W - 30 - 25
ZGR03024 J978W-3
9 10 4
SHUT
DOWN
RELAY
OUTPUT GROUND
SENSOR
FUEL
PUMP
MODULE
AUTO AUTO
OUTPUT
RELAY
DOWN
SHUT
K4
20
BK/LB
K4
20
BK/LB
S136
2
1
3
S128
A142
16
DG/OR
A142
18
DG/OR
A142
14
DG/OR
A142
16
DG/OR
MODULE
FLOW
AIR
MASS
4
Z1
20
BK
Z1
12
BK
Z1
12
BK
Z1
16
BK
G106
S104
10 C131
S134
13
CONTROLLER
MSA
AIR
FLOW
METER
SIGNAL
4
1
2
3
RELAY
PLUG
GLOW
50
GLOW
PLUG
RELAY
CONTROL
SENSE
K155
20
DB
K152
16
WT
A0
14
RD
A0
10
RD
S421
BATT A0
GLOW
PLUG
K154
10
GY
A142
16
DG/OR
S129
(8W-70-8) (8W-70-7)
(8W-15-6)
(8W-15-6)
(8W-15-6)
(8W-10-3)
(8W-70-7)
(8W-30-25)
8W - 30 - 26 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03025
20
FUSE
25A
A20
BATT A0
A19 10
3
30A
FUSE
4
CENTER
DISTRIBUTION
POWER
18
FUSE
15A
A15
A16
B20 B17
B16 B18
F5
16
RD/YL
AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)
F5
16
RD/YL
ST-RUN A21
25
42
CONTROLLER
MSA
AUTOMATIC
SHUTDOWN
RELAY
CONTROL
EGR
SOLENOID
CONTROL
A
(8W-30-28)
K35
16
GY/YL
EGR
SOLENOID
TO
K900
20
PK/BK
K900
20
PK/BK
14 C132
A12
12
RD/TN
F99
18
OR
F99
20
OR
S101
(IN PDC)
RELAY
HEATER
FUEL
D10 D13
D11 D14
B
(8W-30-28)
TO
SOLENOID
EGR
A142
16
DG/OR
A142
16
DG/OR
12 C131
C4 57
S129
A142
16
DG/OR
A142
16
DG/OR
CONTROL
RELAY
SHUTDOWN
AUTOMATIC
MODULE
CONTROL
POWERTRAIN
C
(8W-30-28)
TO
S420
A64
14
OR/DB
G107
Z4
20
BK
Z4
10
BK
S124
(8W-10-16)
(8W-10-3)
(8W-10-18)
(8W-10-3)
(8W-12-20)
(8W-10-8)
(8W-10-15)
(8W-70-7)
(8W-15-8)
(8W-15-8)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
8W - 30 - 27
ZGR03026 J978W-3
A
(8W-30-27)
K35
16
GY/YL
1 2
DG/OR
16
A142
B
(8W-30-27)
FROM
S129
4
Z1
18
BK
Z1
12
BK
Z1
12
BK
Z1
16
BK
S134
S104
10 C131
G106
2
1
Z1
14
BK
FUEL
HEATER
FROM
CONTROL
HEATER
FUEL
A64
14
DG/WT
A64
14
OR/DB
C
(8W-30-27)
MSA
CONTROLLER
FROM
A64
14
OR/DB
9 C131
S420
1
6
M
4
3
UNIT
SENDER
FUEL
A64
16
OR/DB
A64
16
DG/WT
18 C304 10
G40
20
LB/BK
G40
18
LB/BK
3 C131
C4
1
MODULE
CONTROL
POWERTRAIN
G40
18
LB/BK
Z1
16
BK
Z1
12
BK
S304
G305
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
S102
12 C132
S141
C4 4
MODULE
CONTROL
POWERTRAIN
15 C304
EGR
SOLENOID
LOW
FUEL
SENSE
SENSOR
GROUND
RELAY
(8W-15-6)
(8W-15-6)
(8W-70-9)
(8W-15-15)
(8W-15-15)
(8W-70-9)
(8W-70-9)
8W - 30 - 28 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03027
2
1
SENSOR
PRESSURE
OIL
MODULE
CONTROL
POWERTRAIN
C4
42
ENGINE
OIL
PRESSURE
SENSOR
SIGNAL SENSE
SWITCH
LEVEL
COOLANT
8
C4 C4
21
ECT
SENSOR
SIGNAL
COOLANT
LEVEL
SENSOR
1
2
G60
20
GY/YL
G60
20
GY/YL
2 C917
G18
20
PK/BK
G18
20
PK/BK
5 C131
C4 4
SENSOR
GROUND
K167
20
BR/YL
K167
20
BR/YL
S102
K167
20
BR/YL
K167
20
BR/YL
3 C917
12 C132
K167
20
BR/YL
K167
20
BR/YL
S141
B A
C
SENSOR
TEMPERATURE
COOLANT
ENGINE
K222
20
TN/RD
K2
20
TN/BK
K4
20
BK/LB
K4
20
BK/LB
S136
14 33
ENGINE
COOLANT
TEMPERATURE
SIGNAL
GROUND
SENSOR
MODULE
CONTROL
POWERTRAIN
CONTROLLER
MSA
24 C4
STOP
LAMP
SWITCH
SENSE
SPEED
CONTROL
ON/OFF
SWITCH
SENSE SENSE
SWITCH
LAMP
STOP
44 20
3
SWITCH
LAMP
STOP
5
V32
20
YL/RD
V32
20
YL/RD
V32
20
YL/RD
L50
18
WT/TN
L50
18
WT/TN
L50
18
WT/TN
8 9 C132
F9 S337
S312
9
C305
12
1
L53
20
BR
L53
20
BR
L53
20
BR
C234
C132
(8W-70-9)
(8W-70-9)
(8W-70-8)
(8W-70-5)
(8W-70-5)
(8W-33-4)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
8W - 30 - 29
ZGR03028 J978W-3
7
FUSE
20A
8
BATT A250
JUNCTION
BLOCK
C4
F75
18
VT
F75
18
VT
S201
7
16
FUSED
B (+)
DATA
LINK
CONNECTOR
SCI
RECEIVE TRANSMIT
SCI
12
RECEIVE
4 5
RECEIVE
6
SCI
TRANSMIT
G103
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
2 3 C132
H11 H12 C236
D98
20
WT
6
C235
4
NO
CONNECTION
D83
20
BK/PK
D83
20
BK/PK
F14 C234
S200
C235 7
D83
20
BK/PK
C1 20
D83
20
BK/PK
SCI
RECEIVE
RECEIVE
SCI
61
D83
20
BK/PK
CONTROLLER
ANTI-LOCK
BRAKE
CONTROLLER
MSA
D83
20
BK/PK
2 C144
D83
20
BK/PK
C4 25
SCI
RECEIVE TRANSMIT
SCI
45 C4
MODULE
CONTROL
POWERTRAIN
D83
20
BK/PK
D84
20
BK/WT
D84
20
BK/WT
D84
20
BK/WT
3 C144
F15 C234
S142
(8W-12-8)
(8W-10-10)
(8W-12-2)
(8W-12-8)
(8W-30-2)
(8W-35-2)
8W - 30 - 30 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03029
11
DATA
LINK
CONNECTOR
CCD
BUS
(-)
18
D2
18
WT/BK
CONSOLE
OVERHEAD
INSTRUMENT
CLUSTER
C1 20
9
5 C11
8
C4 46
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
VEHICLE
INFORMATION
CENTER
2 C2
RADIO
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
BODY
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
S203
2 C302 2 C231 10 C235
19 C1 C1 9 9
S307
AIRBAG
CONTROL
MODULE
MEMORY
SEAT
MODULE
DRIVER
DOOR
MODULE
PASSENGER
DOOR
MODULE
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
4 C329 12 C334 12 C351
C1
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
CCD
BUS
(-)
D2
18
WT/BK
4 C132
(8W-49-2)
(8W-40-3)
(8W-42-9)
(8W-46-7)
(8W-47-2)
(8W-45-2)
(8W-43-3) (8W-63-15) (8W-60-2)
(8W-61-2)
(8W-62-2)
(8W-60-3)
(8W-61-3)
(8W-62-3)
ZG-RHD 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
8W - 30 - 31
ZGR03030 J978W-3
3
DATA
LINK
CONNECTOR
CCD
BUS
(+)
19
D1
18
VT/BR
CONSOLE
OVERHEAD
INSTRUMENT
CLUSTER
C1 19
8
3 C10
7
C4 26
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
VEHICLE
INFORMATION
CENTER
1 C2
RADIO
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
BODY
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
S204
1 C302 1 C231 11 C235
18 C1 C1 8 8
S306
AIRBAG
CONTROL
MODULE
MEMORY
SEAT
MODULE
DRIVER
DOOR
MODULE
PASSENGER
DOOR
MODULE
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
3 C329 13 C334 13 C351
CCD
BUS
(+) (+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
(+)
BUS
CCD
C1
D1
18
VT/BR
5 C132
(8W-49-2)
(8W-40-3)
(8W-42-9)
(8W-46-7)
(8W-47-2)
(8W-45-2)
(8W-43-3) (8W-63-15) (8W-60-2)
(8W-61-2)
(8W-62-2)
(8W-60-3)
(8W-61-3)
(8W-62-3)
8W - 30 - 32 8W-30 FUEL/IGNITION SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03031
8W-30 FUEL/IGNITION SYSTEMS
INDEX
page page
DESCRIPTION AND OPERATION
ACCELERATOR PEDAL POSITION SENSOR
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AUTOMATIC SHUT DOWN (ASD) RELAY . . . . . 34
AUTOMATIC SHUT DOWN RELAY (DIESEL) . . . 34
BATTERY FEED (DIESEL) . . . . . . . . . . . . . . . . . 33
BATTERY FEED . . . . . . . . . . . . . . . . . . . . . . . . 33
BATTERY TEMPERATURE SENSOR . . . . . . . . . 35
CAMSHAFT POSITION SENSOR . . . . . . . . . . . 36
CCD BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CRANKSHAFT POSITION SENSOR (DIESEL) . . 36
CRANKSHAFT POSITION SENSOR . . . . . . . . . 35
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . 34
DUTY CYCLE EVAP\PURGE SOLENOID . . . . . . 39
EGR SOLENOID (DIESEL) . . . . . . . . . . . . . . . . 39
ENGINE COOLANT TEMPERATURE SENSOR
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE COOLANT TEMPERATURE SENSOR . 36
EVAPORATIVE SYSTEM LEAK DETECTION
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
FUEL HEATER (DIESEL) . . . . . . . . . . . . . . . . . . 39
FUEL INJECTION PUMP (DIESEL) . . . . . . . . . . 38
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 38
FUEL PUMP MODULE (DIESEL) . . . . . . . . . . . . 34
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 34
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . 34
GLOW PLUGS (DIESEL) . . . . . . . . . . . . . . . . . . 39
GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HEATED OXYGEN SENSORS . . . . . . . . . . . . . . 35
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . 39
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 39
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . 33
INSTRUMENTED FIRST INJECTOR (DIESEL) . . 39
INTAKE AIR TEMPERATURE SENSOR . . . . . . . 37
LOW COOLANT LEVEL SWITCH (DIESEL) . . . . 39
LOW IDLE POSITION SWITCH (DIESEL) . . . . . 37
MANIFOLD ABSOLUTE PRESSURE SENSOR . 37
MASS AIR FLOW SENSOR (DIESEL) . . . . . . . . 37
OIL PRESSURE SENSOR (DIESEL) . . . . . . . . . 38
OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . 38
PCM GROUND (DIESEL) . . . . . . . . . . . . . . . . . 34
THROTTLE POSITION SENSOR . . . . . . . . . . . . 36
VEHICLE SPEED SENSOR (DIESEL) . . . . . . . . 35
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 35
WATER IN FUEL SENSOR (DIESEL) . . . . . . . . . 38
DESCRIPTION AND OPERATION
IGNITION SWITCH
Ci rcui t A1 from fuse 8 i n the Power Di stri buti on
Center (PDC) powers four di fferent ci rcui ts through
the i gni ti on swi tch. When the i gni ti on swi tch i s i n
the START or RUN posi ti on, i t connects ci rcui t A1 to
ci rcui t A21.
I n the ACCESSORY or RUN posi ti on, the i gni ti on
swi tch connects to ci rcui t A31. I n the START posi -
ti on, the i gni ti on swi tch connects ci rcui t A1 to ci rcui t
A41. When the i gni ti on swi tch i s i n the RUN posi ti on
i t connects ci rcui t A1 to ci rcui t A22.
Al so i n the START posi ti on, the case grounded
i gni ti on swi tch grounds ci rcui t G9 from the brake
warni ng swi tch.
BATTERY FEED
Ci rcui t F5 from fuse 20 i n the Power Di stri buti on
Center (PDC) suppl i es battery vol tage to cavi ty A22
of the Powertrai n Control Modul e (PCM).
HELPFUL INFORMATION
Ci rcui t F5 al so suppl i es power to the contact si des
of the Automati c Shut Down (ASD) rel ay.
BATTERY FEED (DIESEL)
Battery feed for the Powertrai n Control Modul e
(PCM) i s suppl i ed from several sources. One i s a con-
stant battery feed on ci rcui t F6. Thi s ci rcui t i s pro-
tected by a 15 amp fuse l ocated i n the Power
Di stri buti on Center (PDC)
Battery vol tage i s al so provi ded on ci rcui t F99.
Thi s ci rcui t i s HOT i n the START and RUN posi ti on
and protected by a 15 amp fuse l ocated i n the PDC.
Power for the fuse i s suppl i ed on ci rcui t A21 from the
i gni ti on swi tch.
GROUND
Ci rcui t Z12 connects to cavi ti es A31 and A32 of the
PCM. The Z12 ci rcui t provi des ground for PCM i nter-
nal dri vers that operate hi gh current devi ces l i ke the
i njectors and i gni ti on coi l .
I nternal to the PCM, the ground ci rcui t connects to
the PCM sensor return ci rcui t (from ci rcui t K4).
HELPFUL INFORMATION
I f the system l oses ground for the Z12 ci rcui ts,
the vehi cl e wi l l not operate. Check the connecti on at
the ganged-ground ci rcui t eyel et.
ZG 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 33
PCM GROUND (DIESEL)
Ground for the Powertrai n Control Modul e (PCM)
i s suppl i ed on the Z12 ci rcui t. Thi s ci rcui t connects to
four cavi ti es i n the PCM and termi nates at the PCM
ground l ocati on.
DATA LINK CONNECTOR
Ci rcui t A250 from fuse 11 i n the Power Di stri bu-
ti on Center (PDC) powers ci rcui t F75 through fuse 7
i n the juncti on bl ock. Ci rcui t F75 suppl i es battery
vol tage to the data l i nk connector.
Ci rcui t D84 connects to cavi ty C29 of the PCM.
Ci rcui t D84 i s the SCI transmi t ci rcui t for the Pow-
ertrai n Control Modul e (PCM). Ci rcui t D83 connects
to cavi ty C27 of the PCM and cavi ty A3 of the Con-
trol l er- Anti Lock Brakes. Ci rcui t D83 i s the SCI
recei ve ci rcui t for the PCM.
Ci rcui ts D83 and D98 from the speed proporti onal
steeri ng modul e connect to the data l i nk connector.
Ci rcui ts Z1 and Z2 provi de ground for the data l i nk
connector.
AUTOMATIC SHUT DOWN (ASD) RELAY
When the i gni ti on swi tch i s i n ei ther the START or
RUN posi ti on, i t connects ci rcui t A1 from fuse 8 i n
the Power Di stri buti on Center (PDC) to ci rcui t A21.
Ci rcui t A21 powers ci rcui t F99 through PDC fuse 18.
Ci rcui t F99 feeds the coi l si de of the Automati c Shut
Down (ASD) rel ay. The Powertrai n Control Modul e
(PCM) provi des ground for the rel ay on ci rcui t K900.
Ci rcui t K900 connects to cavi ty C3 of the PCM.
When the PCM grounds the ASD rel ay, contacts
i nsi de the rel ay cl ose and connect ci rcui t F5 from
fuse 20 i n the PDC to ci rcui t A142. Ci rcui t A142
spl i ces to, fuel i njectors, i gni ti on coi l and the
upstream and downstream heated oxygen sensors.
Ci rcui t A142 al so connects to cavi ty C12 of the PCM.
HELPFUL INFORMATION
Al ong wi th suppl yi ng vol tage to the coi l si de of the
ASD rel ay, ci rcui t F99 al so suppl i es vol tage to the
coi l si de of the fuel pump rel ay.
AUTOMATIC SHUT DOWN RELAY (DIESEL)
Power for the coi l and contact si de of the Auto-
mati c Shut Down (ASD) rel ay i s suppl i ed on ci rcui t
F5. Thi s ci rcui t i s HOT at al l ti mes and protected by
a 25 amp fuse l ocated i n the Power Di stri buti on Cen-
ter (PDC).
Ground for the coi l si de of the rel ay i s control l ed by
the Powertrai n Control Modul e (PCM) on ci rcui t
K900.
When the PCM provi des a ground for the coi l si de
of the rel ay the contacts i n the rel ay CLOSE and
connect ci rcui ts F5 and A142. The A142 ci rcui t sup-
pl i es power to vari ous components and modul es i n
the fuel system.
HELPFUL INFORMATION
Check the 25 amp fuse l ocated i n the PDC
Refer to the appropri ate secti on of the servi ce
manual or Di agnosti c Test Procedures manual
FUEL PUMP RELAY
When the i gni ti on swi tch i s i n ei ther the START or
RUN posi ti ons, i t connects ci rcui t A1 from fuse 8 i n
the Power Di stri buti on Center (PDC) to ci rcui t A21.
Ci rcui t A21 powers ci rcui t F99 through PDC fuse 18.
Ci rcui t F99 suppl i es battery vol tage to the coi l si de of
the fuel pump rel ay. The Powertrai n Control Modul e
(PCM) provi des ground for the rel ay on ci rcui t K81.
Ci rcui t K81 connects to cavi ty C19 of the PCM.
When the PCM grounds the fuel pump rel ay, con-
tacts i nsi de the rel ay cl ose and connect ci rcui t A61
from fuse 16 i n the PDC to ci rcui t A64. Ci rcui t A64
feeds the fuel pump motor (part of the i n-tank fuel
pump modul e).
HELPFUL INFORMATION
Ci rcui t F99 al so powers the coi l si de of the Auto-
mati c Shut Down (ASD) rel ay.
FUEL PUMP MODULE
The i n-tank fuel pump modul e contai ns the fuel
pump motor and fuel l evel sensor.
FUEL PUMP MOTOR
When the fuel pump rel ay contacts cl ose, the rel ay
feeds the fuel pump motor. Ci rcui t A64 from the
rel ay powers the fuel pump modul e. Ci rcui t Z1 pro-
vi des ground for the fuel pump motor.
FUEL LEVEL SENSOR
The fuel l evel sensor i s a vari abl e resi stor. Ci rcui t
G40 provi des the fuel l evel i nput to cavi ty C26 of the
Powertrai n Control Modul e (PCM). The PCM broad-
casts fuel l evel data on the CCD bus. The mi cro-pro-
cessor i n the i nstrument cl uster recei ves the message
on the CCD bus, cal cul ates fuel gauge needl e posi ti on
and adjusts the gauge.
FUEL PUMP MODULE (DIESEL)
The i n-tank fuel pump modul e contai ns the fuel
pump motor and fuel l evel sensor.
FUEL PUMP MOTOR
When the fuel pump rel ay contacts cl ose, the rel ay
feeds the fuel pump motor. Ci rcui t A64 from the
rel ay powers the fuel pump motor. Ci rcui t Z1 pro-
vi des ground for the fuel pump motor.
8W - 30 - 34 8W - 30 FUEL/IGNITION SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
FUEL LEVEL SENSOR
The fuel l evel sensor i s a vari abl e resi stor. Ci rcui t
G40 provi des the fuel l evel i nput to the Powertrai n
Control Modul e (PCM). The PCM broadcasts fuel
l evel data on the CCD bus. The mi cro-processor i n
the i nstrument cl uster recei ves the message on the
CCD bus, cal cul ates fuel gauge needl e posi ti on and
adjusts the gauge.
VEHICLE SPEED SENSOR
Ci rcui t K6 suppl i es 5 vol ts from the Powertrai n
Control Modul e (PCM) to the vehi cl e speed sensor.
The K6 ci rcui t connects to cavi ty B31 of the PCM.
Ci rcui t G7 from the vehi cl e speed sensor provi des
an i nput si gnal to the PCM. The G7 ci rcui t connects
to cavi ty B27 of the PCM.
The PCM provi des a ground for the vehi cl e speed
sensor si gnal (ci rcui t G7) through ci rcui t K4. Ci rcui t
K4 connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Ci rcui t K4 spl i ces to suppl y ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Camshaft posi ti on sensor
Crankshaft posi ti on sensor
Downstream heated oxygen sensor
Engi ne cool ant temperature sensor
Fuel pump modul e
I ntake ai r temperature sensor
Mani fol d absol ute pressure sensor
Oi l pressure sensor
Powertrai n control modul e
Throttl e posi ti on sensor
Transmi ssi on sol enoi d assembl y
Upstream heated oxygen sensor
Vehi cl e speed control swi tch
VEHICLE SPEED SENSOR (DIESEL)
Ci rcui t K7 suppl i es vol tage from the Powertrai n
Control Modul e (PCM) to the vehi cl e speed sensor.
Ci rcui t G7 from the vehi cl e speed sensor provi des
an i nput si gnal to the PCM.
The PCM provi des a ground for the vehi cl e speed
sensor si gnal (ci rcui t G7) through ci rcui t K4.
HEATED OXYGEN SENSORS
When the Automati c Shut Down (ASD) rel ay con-
tacts cl ose, ci rcui t A142 suppl i es vol tage to the
upstream and downstream heated oxygen sensors.
Ci rcui t K41 del i vers the si gnal from the upstream
heated oxygen sensor to the Powertrai n Control Mod-
ul e (PCM). Ci rcui t K41 connects to cavi ty A24 of the
PCM. Ci rcui t K141 suppl i es the si gnal from the
downstream heated oxygen sensor to the PCM. Ci r-
cui t K141 connects to PCM cavi ty A25.
The PCM provi des a ground for the heated oxygen
sensor si gnal s (ci rcui ts K41 and K141) through ci r-
cui t K4. Ci rcui t K4 connects to cavi ty A4 of the PCM
connector.
Ci rcui t Z12 provi des ground for the heater ci rcui t
i n each sensor.
HELPFUL INFORMATION
Ci rcui t A142 al so suppl i es battery vol tage to the
fuel i njectors, i gni ti on coi l , and generator.
Ci rcui t K4 spl i ces to suppl y ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Camshaft posi ti on sensor
Crankshaft posi ti on sensor
Engi ne cool ant temperature sensor
Fuel pump modul e
I ntake ai r temperature sensor
Mani fol d absol ute pressure sensor
Oi l pressure sensor
Powertrai n control modul e
Throttl e posi ti on sensor
Transmi ssi on sol enoi d assembl y
Vehi cl e speed control swi tch
Vehi cl e speed sensor
BATTERY TEMPERATURE SENSOR
The Powertrai n Control Modul e (PCM) determi nes
battery temperature on ci rcui t T222. Ci rcui t T222
connects the PCM to the battery temperature sensor.
Ci rcui t T222 connects to cavi ty C15 of the PCM. Ci r-
cui t K4 provi des ground for the sensor and connects
to PCM cavi ty A4.
CRANKSHAFT POSITION SENSOR
The Powertrai n Control Modul e (PCM) suppl i es 5
vol ts to the crankshaft posi ti on sensor on ci rcui t K25.
Ci rcui t K25 connects to cavi ty A17 of the PCM.
The PCM recei ves the crankshaft posi ti on sensor
si gnal on ci rcui t K27. Ci rcui t K27 connects to cavi ty
A8 of the PCM.
The PCM provi des a ground for the crankshaft
posi ti on sensor (ci rcui t K27) through ci rcui t K4. Ci r-
cui t K4 connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Ci rcui t K25 spl i ces to suppl y 5 vol ts to the cam-
shaft posi ti on sensor, mani fol d absol ute pressure sen-
sor and throttl e posi ti on sensor.
Ci rcui t K4 spl i ces to suppl y ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Camshaft posi ti on sensor
Downstream heated oxygen sensor
Engi ne cool ant temperature sensor
Fuel pump modul e
I ntake ai r temperature sensor
ZG 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 35
DESCRIPTION AND OPERATION (Continued)
Mani fol d absol ute pressure sensor
Oi l pressure sensor
Powertrai n control modul e
Throttl e posi ti on sensor
Transmi ssi on sol enoi d assembl y
Upstream heated oxygen sensor
Vehi cl e speed control swi tch
Vehi cl e speed sensor
CRANKSHAFT POSITION SENSOR (DIESEL)
The Powertrai n Control Modul e (PCM) suppl i es
vol tage to the crankshaft posi ti on sensor on ci rcui t
K24.
The PCM provi des a ground for the crankshaft
posi ti on sensor (ci rcui t K24) through ci rcui t K4.
CAMSHAFT POSITION SENSOR
The Powertrai n Control Modul e (PCM) suppl i es 5
vol ts to the camshaft posi ti on sensor (i n di stri butor)
on ci rcui t K25. Ci rcui t K25 connects to cavi ty A17 of
the PCM.
The PCM recei ves the camshaft posi ti on sensor si g-
nal on ci rcui t K24. Ci rcui t K24 connects to cavi ty
A18 of the PCM.
The PCM provi des a ground for the camshaft posi -
ti on sensor si gnal (ci rcui t K24) through ci rcui t K4.
Ci rcui t K4 connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Ci rcui t K25 spl i ces to suppl y 5 vol ts to the
crankshaft posi ti on sensor, mani fol d absol ute pres-
sure sensor, and throttl e posi ti on sensor.
Ci rcui t K4 spl i ces to suppl y ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Crankshaft posi ti on sensor
Downstream heated oxygen sensor
Engi ne cool ant temperature sensor
Fuel pump modul e
I ntake ai r temperature sensor
Mani fol d absol ute pressure sensor
Oi l pressure sensor
Powertrai n control modul e
Throttl e posi ti on sensor
Transmi ssi on sol enoi d assembl y
Upstream heated oxygen sensor
Vehi cl e speed control swi tch
Vehi cl e speed sensor
ENGINE COOLANT TEMPERATURE SENSOR
The engi ne cool ant temperature sensor provi des an
i nput to the Powertrai n Control Modul e (PCM) on
ci rcui t K2. From ci rcui t K2, the engi ne cool ant tem-
perature sensor draws up to 5 vol ts from the PCM.
The sensor i s a vari abl e resi stor. As cool ant temper-
ature changes, the resi stance i n the sensor changes,
causi ng a change i n current draw. The K2 ci rcui t
connects to cavi ty A16 of the PCM.
The PCM provi des a ground for the engi ne cool ant
temperature sensor si gnal (ci rcui t K2) through ci rcui t
K4. Ci rcui t K4 connects to cavi ty A4 of the PCM con-
nector.
HELPFUL INFORMATION
Ci rcui t K4 spl i ces to suppl y ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Camshaft posi ti on sensor
Crankshaft posi ti on sensor
Downstream heated oxygen sensor
Fuel pump modul e
I ntake ai r temperature sensor
Mani fol d absol ute pressure sensor
Oi l pressure sensor
Powertrai n control modul e
Throttl e posi ti on sensor
Transmi ssi on sol enoi d assembl y
Upstream heated oxygen sensor
Vehi cl e speed control swi tch
Vehi cl e speed sensor
ENGINE COOLANT TEMPERATURE SENSOR
(DIESEL)
The Engi ne Cool ant Temperature (ECT) sensor on
thi s engi ne appl i cati on i s a dual functi on sensor. I t
provi des a engi ne cool ant temperature i nput to the
Powertrai n Control Modul e (PCM) on Ci rcui ts K2
and Ci rcui t K222.
Ground for the sensor i s suppl i ed on ci rcui t K4.
The sensor i s a vari abl e resi stor. As engi ne cool ant
temperature changes the resi stance on the K4 ci rcui t
changes.
EVAPORATIVE SYSTEM LEAK DETECTION PUMP
Vehi cl e bui l t for sal e i n the State of Cal i forni a are
equi pped wi th an evaporati ve system l eak detecti on
pump.
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from fuse 8 i n the
Power Di stri buti on Center (PDC) to ci rcui t A21. Ci r-
cui t A21 powers ci rcui t F99 through PDC fuse 18.
Ci rcui t F99 feeds the l eak detecti on pump.
On ci rcui ts J96 and J95, the PCM operates the
l eak detecti on pump. Ci rcui t J96 connects to cavi ty
C14 of the PCM. Ci rcui t J95 connects to PCM cavi ty
C10.
THROTTLE POSITION SENSOR
From the Powertrai n Control Modul e (PCM), ci r-
cui t K25 suppl i es 5 vol ts to the throttl e posi ti on sen-
sor (TPS). Ci rcui t K25 connects to cavi ty A17 of the
PCM.
8W - 30 - 36 8W - 30 FUEL/IGNITION SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
Ci rcui t K22 del i vers the TPS si gnal to the PCM.
Ci rcui t K22 connects to cavi ty A23 of the PCM.
The PCM provi des a ground for the throttl e posi -
ti on sensor si gnal (ci rcui t K22) through ci rcui t K4.
Ci rcui t K4 connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Refer to Group 14 for throttl e posi ti on sensor oper-
ati on.
Ci rcui t K25 spl i ces to suppl y 5 vol ts to the mani -
fol d absol ute pressure sensor, camshaft posi ti on sen-
sor, and crankshaft posi ti on sensor.
Ci rcui t K4 spl i ces to suppl y ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Camshaft posi ti on sensor
Crankshaft posi ti on sensor
Downstream heated oxygen sensor
Engi ne cool ant temperature sensor
Fuel pump modul e
I ntake ai r temperature sensor
Mani fol d absol ute pressure sensor
Oi l pressure sensor
Powertrai n control modul e
Transmi ssi on sol enoi d assembl y
Upstream heated oxygen sensor
Vehi cl e speed control swi tch
Vehi cl e speed sensor
ACCELERATOR PEDAL POSITION SENSOR
(DIESEL)
Power for the accel erator pedal posi ti on sensor i s
suppl i ed by the Powertrai n Control Modul e (PCM) on
ci rcui t K6. Thi s i s a 5 vol t feed from the PCM.
Ci rcui t K22 provi des the pedal posi ti on i nput to
the PCM. Ground for the sensor i s suppl i ed from the
PCM on ci rcui t K4.
LOW IDLE POSITION SWITCH (DIESEL)
Ci rcui t K151 connects from the Powertrai n Control
Modul e (PCM) to the l ow i dl e posi ti on swi tch. Thi s
ci rcui t provi des the l ow i dl e swi tch i nput.
Ground for the swi tch i s provi ded on ci rcui t K4.
MANIFOLD ABSOLUTE PRESSURE SENSOR
From the Powertrai n Control Modul e (PCM), ci r-
cui t K25 suppl i es 5 vol ts to the mani fol d absol ute
pressure (MAP) sensor. Ci rcui t K25 connects to cav-
i ty A17 of the PCM.
Ci rcui t K70 del i vers the MAP si gnal to the PCM.
Ci rcui t K70 connects to cavi ty A27 of the PCM.
The PCM provi des a ground for the MAP sensor
si gnal (ci rcui t K70) through ci rcui t K4. Ci rcui t K4
connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Refer to Group 14 for MAP sensor operati on.
Ci rcui t K25 spl i ces to suppl y 5 vol ts to the cam-
shaft posi ti on sensor, crankshaft posi ti on sensor and
throttl e posi ti on sensor.
Ci rcui t K4 spl i ces to suppl y ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Camshaft posi ti on sensor
Crankshaft posi ti on sensor
Downstream heated oxygen sensor
Engi ne cool ant temperature sensor
Fuel pump modul e
I ntake ai r temperature sensor
Oi l pressure sensor
Powertrai n control modul e
Throttl e posi ti on sensor
Transmi ssi on sol enoi d assembl y
Upstream heated oxygen sensor
Vehi cl e speed control swi tch
Vehi cl e speed sensor
MASS AIR FLOW SENSOR (DIESEL)
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects Ci rcui t A1 from fuse 8 i n the
Power Di sstri buti on Center (PDC) to ci rcui t A21. Ci r-
cui t A21 powers ci rcui t F99 through PDC fuse 18.
Ci rcui t F99 feeds the mass ai r fl ow sensor.
Ci rcui t K155 provi des the i nput to the PCM.. A
sensor ground i s provi ded by the PCM on ci rcui t K4.
Ground i s al so provi ded on ci rcui t Z1.
INTAKE AIR TEMPERATURE SENSOR
The i ntake ai r temperature sensor provi des an
i nput to the Powertrai n Control Modul e (PCM) on
ci rcui t K21. Ci rcui t K21 connects to cavi ty A15 of the
PCM.
From ci rcui t K21, the i ntake ai r temperature sen-
sor draws vol tage from the PCM. The sensor i s a
vari abl e resi stor. As i ntake ai r temperature changes,
the resi stance i n the sensor changes, causi ng a
change i n current draw.
The PCM provi des a ground for the i ntake ai r tem-
perature sensor si gnal (ci rcui t K21) through ci rcui t
K4. Ci rcui t K4 connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Ci rcui t K4 spl i ces to suppl y ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Camshaft posi ti on sensor
Crankshaft posi ti on sensor
Downstream heated oxygen sensor
Engi ne cool ant temperature sensor
Fuel pump modul e
Mani fol d absol ute pressure sensor
Oi l pressure sensor
Powertrai n control modul e
Throttl e posi ti on sensor
ZG 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 37
DESCRIPTION AND OPERATION (Continued)
Transmi ssi on sol enoi d assembl y
Upstream heated oxygen sensor
Vehi cl e speed control swi tch
Vehi cl e speed sensor
OIL PRESSURE SENSOR
The oi l pressure sensor i s a vari abl e resi stor. A
change i n engi ne oi l pressure changes the resi stance
i n the sendi ng uni t whi ch al ters the si gnal sensed by
the Powertrai n Control Modul e on ci rcui t G6. Ci rcui t
G6 connects to cavi ty B23 of the PCM.
The PCM provi des ground for the oi l pressure sen-
sor on ci rcui t K4. Ci rcui t K4 connects to cavi ty A4 of
the PCM.
The PCM broadcasts the oi l pressure data on the
CCD bus. The mi cro-processor i n the i nstrument cl uster
recei ves the si gnal from the CCD bus, cal cul ates oi l
pressure and adjusts the gauge needl e posi ti on.
The Body Control Modul e (BCM) al so recei ves the
oi l pressure data broadcast by the PCM on the CCD
bus. I f oi l pressure drops bel ow a cal i brated pressure,
the BCM sounds an audi bl e chi me and i l l umi nates
the oi l pressure warni ng l amp.
OIL PRESSURE SENSOR (DIESEL)
The oi l pressure sensor i s a vari abl e resi stor. A
change i n engi ne oi l pressure changes the resi stance
i n the sendi ng uni t whi ch al ters the si gnal sensed by
the Powertrai n Control Modul e on ci rcui t G60.
The PCM provi des ground for the oi l pressure sen-
sor on ci rcui t K4.
The PCM broadcasts the oi l pressure data on the
CCD bus. The mi cro-processor i n the i nstrument cl uster
recei ves the si gnal from the CCD bus, cal cul ates oi l
pressure and adjusts the gauge needl e posi ti on.
The Body Control Modul e (BCM) al so recei ves the
oi l pressure data broadcast by the PCM on the CCD
bus. I f oi l pressure drops bel ow a cal i brated pressure,
the BCM sounds an audi bl e chi me and i l l umi nates
the oi l pressure warni ng l amp.
WATER IN FUEL SENSOR (DIESEL)
The water i n fuel sensor provi des an i nput to the
Powertrai n Control Modul e (PCM) on ci rcui t G123.
The PCM provi des ground for the water i n fuel
sensor si gnal (ci rcui t G123) through ci rcui t K4.
FUEL INJECTORS
When the Automati c Shut Down (ASD) rel ay con-
tacts cl ose, they connect ci rcui ts F5 and A142. Ci rcui t
A142 suppl i es vol tage to the fuel i njectors. Each
i njector has a separate ground ci rcui t control l ed by
the Powertrai n Control Modul e (PCM).
Ci rcui t K11 provi des ground for i njector number one.
The K11 ci rcui t connects to cavi ty B4 of the PCM.
Ci rcui t K12 provi des ground for i njector number two.
The K12 ci rcui t connects to cavi ty B15 of the PCM.
Ci rcui t K13 provi des ground for i njector number
three. The K13 ci rcui t connects to cavi ty B5 of the PCM.
Ci rcui t K14 provi des ground for i njector number four.
The K14 ci rcui t connects to cavi ty B16 of the PCM.
Ci rcui t K38 provi des ground for i njector number fi ve.
The K38 ci rcui t connects to cavi ty B6 of the PCM.
Ci rcui t K58 provi des ground for i njector number si x.
The K58 ci rcui t connects to cavi ty B12 of the PCM.
On the 5.2L engi ne, ci rcui t K17 provi des ground
for i njector number seven. The K17 ci rcui t connects
to cavi ty B2 of the PCM.
Al so on the 5.2L engi ne, ci rcui t K18 provi des
ground for i njector number ei ght. The K18 ci rcui t
connects to cavi ty B13 of the PCM.
HELPFUL INFORMATION
Ci rcui t A142 spl i ces to suppl y vol tage to the fuel
i njectors, i gni ti on coi l , PCM, generator, and heated
oxygen sensors.
For i nformati on about fuel i njector operati on,
refer to Group 14.
FUEL INJECTION PUMP (DIESEL)
The fuel i njecti on pump used on thi s engi ne appl i -
cati on performs several functi ons. Each of these i s
descri bed as fol l ows.
FUEL SHUT-OFF SOLENOID
Power for the fuel shut-off sol enoi d i s suppl i ed on
ci rcui t A142. Thi s ci rcui t i s HOT when the contacts
i n the di esel Powertrai n Control Modul e (PCM) rel ay
are CLOSED. Ground for the sol enoi d i s control l ed
by the PCM on ci rcui t K153.
SOLENOID VALVE
Power for the sol enoi d i s suppl i ed on ci rcui t A142.
Thi s ci rcui t i s HOT when the contacts i n the di esel
Powertrai n Control Modul e (PCM) rel ay are
CLOSED. Ground for the sol enoi d i s control l ed by
the PCM on ci rcui t K238.
FUEL TEMP SENSOR
Ci rcui t K156 connects between the Powertrai n
Control Modul e (PCM) and the fuel temperature sen-
sor. The sensor i s a vari abl e resi stor. As fuel temper-
ature changes the resi stance on ci rcui t K156
changes. Ground for the sensor i s suppl i ed on ci rcui t
K4.
CONTROL SLEEVE POSITION SENSOR
Ci rcui t K134 connects between the Powertrai n
Control Modul e (PCM) and the control sl eeve posi ti on
sensor. Thi s ci rcui t i s the posi ti on i nput to the PCM.
Ci rcui t K57 i s used for the mi ddl e tap, and ci rcui t
K135 i s used for the measure coi l .
8W - 30 - 38 8W - 30 FUEL/IGNITION SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
FUEL QUANTITY ACTUATOR
Power for the fuel quanti ty Actuator i s suppl i ed on
ci rcui t A142. Thi s ci rcui t i s HOT when the contacts
i n the di esel Powertrai n Control Modul e (PCM) rel ay
are CLOSED. Ground for the Actuator i s control l ed
by the PCM on ci rcui t K140.
FUEL HEATER (DIESEL)
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from fuse 8 i n the
Power Di stri buti on Center (PDC) to ci rcui t A21. Ci r-
cui t A21 powers ci rcui t F99 through PDC fuse 18.
Ci rcui t F99 feeds the coi l si de of the fuel heater
rel ay. Ground for the rel ay i s suppl i ed by ci rcui t Z4.
When the contacts of the fuel heater rel ay are
cl osed they connect ci rcui t A12 from fuse 4 of the
PDC and ci rcui t A64. Ci rcui t A64 suppl i es vol tage to
the fuel heater. Ground for the fuel heater i s sup-
pl i ed on ci rcui t Z1.
INSTRUMENTED FIRST INJECTOR (DIESEL)
The i nstrumented fi rst i njector i s used to provi de a
i nput to the Powertrai n Control Modul e (PCM). Ci r-
cui t K67 connects from the PCM connector, cavi ty 12,
to the i njector and i s used as the si gnal wi re.
Ci rcui t K68, from cavi ty 11 of the PCM connector,
i s used for a return from the i njector.
GLOW PLUGS (DIESEL)
The gl ow pl ugs used on thi s vehi cl e are control l ed
by the Powertrai n Control Modul e (PCM) and the
gl ow pl ug rel ay. Power for the coi l si de of the rel ay i s
suppl i ed on ci rcui t A142. Thi s ci rcui t i s HOT when
the contacts i n the di esel Powertrai n Control Modul e
(PCM) rel ay are CLOSED.
The ground si de of the rel ay i s control l ed by the
PCM on ci rcui t K152. Thi s ci rcui t connects to cavi ty
50 of the PCM connector.
When the PCM determi nes a need for gl ow pl ug
operati on i t suppl i es a ground path on ci rcui t K152.
Thi s causes the contacts i n the rel ay to CLOSE con-
necti ng ci rcui t A0 and K154. The A0 ci rcui t i s HOT
at al l ti mes. Ci rcui t K154 connects from the rel ay to
the gl ow pl ugs.
The gl ow pl ugs are case grounded.
IGNITION COIL
When the Automati c Shut Down (ASD) rel ay contacts
cl ose, ci rcui t A142 suppl i es vol tage to the i gni ti on coi l .
The Powertrai n Control Modul e (PCM) control s the
ground path for the i gni ti on coi l on ci rcui t K19. Ci rcui t
K19 connects to cavi ty A7 of the PCM.
HELPFUL INFORMATION
Ci rcui t A142 spl i ces to suppl y vol tage to the fuel
i njectors, PCM, heated oxygen sensors, and genera-
tor.
IDLE AIR CONTROL (IAC) MOTOR
The Powertrai n Control Modul e (PCM) operates
the i dl e ai r control motor through 4 ci rcui ts; K39,
K40, K59, and K60. Each ci rcui t connects to separate
cavi ti es i n the PCM connector.
Ci rcui t K39 connects to cavi ty A20 of the PCM
Ci rcui t K40 connects to cavi ty A11 of the PCM
Ci rcui t K59 connects to cavi ty A10 of the PCM
Ci rcui t K60 connects to cavi ty A19 of the PCM
DUTY CYCLE EVAP\PURGE SOLENOID
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from fuse 8 i n the Power
Di stri buti on Center (PDC) to ci rcui t A21. Ci rcui t A21
powers ci rcui t F99 through PDC fuse 18. Ci rcui t F99
powers to the Duty Cycl e EVAP/Purge sol enoi d.
The Powertrai n Control Modul e (PCM) provi des
the ground path for the sol enoi d on ci rcui t K52. Ci r-
cui t K52 connects to cavi ty C20 of the PCM.
EGR SOLENOID (DIESEL)
Power for the EGR sol enoi d i s suppl i ed on ci rcui t
A142. Thi s ci rcui t i s HOT when the contacts i n the
di esel Powertrai n Control Modul e (PCM) rel ay are
CLOSED. Ground for the sol enoi d i s suppl i ed on ci r-
cui t Z1.
The PCM control s the operati on of the sol enoi d by
suppl yi ng a ground path for ci rcui t K35. Thi s ci rcui t
connects to cavi ty 25 of the PCM connector
LOW COOLANT LEVEL SWITCH (DIESEL)
When the l ow cool ant l evel swi tch cl oses, i t con-
nects ci rcui t G18 from the Powertrai n Control Mod-
ul e (PCM) and ci rcui t K167. Ci rcui t K167 connects to
ci rcui t K4 sensor ground ci rcui t.
When the l ow cool ant l evel swi tch i s cl osed the
PCM recei ves a si gnal from ci rcui t G18.
CCD BUS
Ci rcui ts D1 and D2 connect the Powertrai n Control
Modul e (PCM) to the CCD Bus. Ci rcui t D1 connects
to cavi ty C30 of the PCM. Ci rcui t D2 connects to cav-
i ty C28 of the PCM. Ci rcui ts D1 and D2 are a
twi sted pai r of wi res.
Several modul es and control l ers broadcast and
recei ve data on the CCD Bus. Each modul e or con-
trol l er i s enabl ed to recei ve onl y certai n messages.
The PCM broadcasts the fol l owi ng messages on the
CCD bus.
Engi ne RPM
I njector on-ti me and di stance pul ses
Vehi cl e speed
Engi ne temperature
Battery temperature
Oi l pressure
ZG 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 39
DESCRIPTION AND OPERATION (Continued)
8W-31 TRANSMISSION CONTROL SYSTEM
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Page
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
MSA Control l er . . . . . . . . . . . . . . . . . . . . . . 8W-31-6
O/D Sol enoi d Control . . . . . . . . . . . . . . . . . 8W-31-2
Output Shaft Speed Sensor . . . . . . . . . . . 8W-31-4, 6
Overdri ve Pressure Swi tch . . . . . . . . . . . . . 8W-31-5
Pedal Posi ti on Sensor . . . . . . . . . . . . . . . . . 8W-31-6
Power Di stri buti on Center . . . . . . . . . . . . . 8W-31-2
Powertrai n Control Modul e . . . . . 8W-31-2, 3, 4, 5, 6
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 4
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 4
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
Component Page
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 4
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
Shi ft I nterl ock . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-31-5
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . 8W-31-4
Torque Converter Cl utch Sol enoi d . . . . . . . . 8W-31-2
Transmi ssi on Control Rel ay . . . . . . . . . . . . 8W-31-2
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . 8W-31-2
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . 8W-31-3
Vari abl e Force Sol enoi d . . . . . . . . . . . . . . . . 8W-31-2
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . 8W-31-4
ZG 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
17
FUSE
15A
A13
BATT A0
A14
A7 A10
A8 A6
F92
18
LG
TRANSMISSION
CONTROL
RELAY
2
GENERATOR
K72
18
DG/VT
K72
18
DG/VT
3 C144
C25
C3
GENERATOR
FIELD
SOURCE
K72
18
DG/VT
T20
18
LB
T20
18
LB
1 C131
6
1
TRANSMISSION
SOLENOID
ASSEMBLY
5 7
B21 B8 B11
T60
18
BR
T59
18
PK
T22
18
DG/LB
C2 C2 C2
TORQUE
CONVERTER
CLUTCH
SOLENOID
CONTROL
CONTROL
SOLENOID
FORCE
VARIABLE O/D
CONTROL
RELAY
TRANSMISSION
C2 B30
T66
20
BR/OR
T66
20
BR/OR
7 C132
CENTER
DISTRIBUTION
POWER
CENTER
DISTRIBUTION
POWER
MODULE
CONTROL
POWERTRAIN
POWERTRAIN
CONTROL
MODULE
SOLENOID
CONTROL
TORQUE
CLUTCH
CONVERTER
SOLENOID
FORCE
SOLENOID
VARIABLE
SOLENOID
CONTROL
O/D
(8W-30-3)
(8W-30-3)
(8W-10-3)
(8W-10-3)
(8W-10-3)
(8W-20-3)
(8W-10-14)
8W - 31 - 2 8W-31 TRANSMISSION SYSTEM ZG-RHD
J978W-3 ZGR03101
B31
4
2
TRANSMISSION
SOLENOID
ASSEMBLY
3 8
B29 A4 B1
T25
18
LG
K4
18
BK/LB
T54
18
VT
C2 C1 C2
TRANSMISSION
TEMPERATURE
SENSOR
SIGNAL
GROUND
SENSOR GOVERNOR
PRESSURE
SIGNAL
S135
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
S127
K6
18
VT/WT
K6
18
VT/WT
S132
4.0L 5.2L
5V
SUPPLY
C2
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
POWERTRAIN
(8W-30-6)
(8W-30-6)
(8W-70-2)
(8W-70-2)
(8W-70-3)
ZG-RHD 8W-31 TRANSMISSION SYSTEM 8W - 31 - 3
ZGR03102 J978W-3
C2
B28 B25
C2 C2
B31 B27
C2
OUTPUT
SHAFT
SPEED
SENSOR
SIGNAL
(+) (-)
SIGNAL
SENSOR
SPEED
SHAFT
OUTPUT
1 2
SENSOR
SPEED
SHAFT
OUTPUT
T14
18
LG/WT
T13
18
DB/BK
THROTTLE
POSITION
SENSOR
**3 **2
**1
THROTTLE
POSITION
SENSOR
SIGNAL
C1
A23 A17
C1
SUPPLY
5V
K22
18
OR/DB
K25
20
WT/BK
K4
20
BK/LB
K4
20
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
20
BK/LB
S127 S136
SUPPLY
5V
SIGNAL
SENSOR
SPEED
VEHICLE
SENSOR
GROUND
A4
C1
K4
18
BK/LB
K6
18
VT/WT
G7
18
WT/OR
S135 S132 S131
2 1 3
G7
18
WT/OR
K6
18
VT/WT
K4
18
BK/LB
VEHICLE
SPEED
SENSOR
SIGNAL
SUPPLY
5V SENSOR
GROUND
VEHICLE
SPEED
SENSOR
4.0L 5.2L
MODULE
CONTROL
POWERTRAIN
K25
18
WT/BK
S133
*1 *2
*3
* 5.2L V-8
** 4.0L I-6
(8W-70-2) (8W-70-4)
(8W-70-3) (8W-70-2) (8W-70-2)
(8W-30-8)
(8W-30-9)
(8W-30-10)
(8W-30-17)
(8W-30-7)
8W - 31 - 4 8W-31 TRANSMISSION SYSTEM ZG-RHD
J978W-3 ZGR03103
ST-RUN A21
10A
FUSE
5 12
FUSE
10A
RUN A22
F87
20
BK/WT
F87
20
BK/WT
S215
2
1
SHIFT
INTERLOCK
L53
20
BR
L53
20
BR
L53
18
BR
F13 C234
S206
2
1
STOP
LAMP
SWITCH
L53
20
BR
Z1
20
BK
Z1
14
BK
Z1
14
BK
G304
S202
2 C301
Z1
16
BK
Z1
20
BK
S216
2
6
7
5
C3
C13
T9
18
OR
T9
20
OR
F20 C234
C24 C3
SENSE
SWITCH
LAMP
STOP
C3 C6
G68
20
BR/YL
G68
18
BR/YL
9 C235
OVERDRIVE
OFF
LAMP
DRIVER
F71
20
PK/DG
F71
20
PK/DG
S218
JUNCTION
BLOCK
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
POWERTRAIN
8 C9 C9 9
OVERDRIVE
OFF
SWITCH
SENSE
SWITCH
PRESSURE
OVERDRIVE
SWITCH POD)
(PART OF
(8W-12-5) (8W-12-10)
(8W-12-5)
(8W-33-2)
(8W-15-18)
(8W-15-18)
(8W-15-17)
(8W-12-10)
(8W-10-8) (8W-10-8)
(8W-12-2)
(8W-30-4)
(8W-30-10)
(8W-30-4)
ZG-RHD 8W-31 TRANSMISSION SYSTEM 8W - 31 - 5
ZGR03104 J978W-3
C2
B28 B25
C2
65 57
OUTPUT
SHAFT
SPEED
SENSOR
SIGNAL
(+) (-)
SIGNAL
SENSOR
SPEED
SHAFT
OUTPUT
1 2
SENSOR
SPEED
SHAFT
OUTPUT
T14
18
LG/WT
T13
18
DB/BK
THROTTLE
POSITION
SENSOR
SIGNAL
15
SUPPLY
5V
SWITCH
POSITION
IDLE
LOW
55
K255
20
WT/DG
K151
20
WT
K6
20
VT/WT
3 5 7
K6
20
VT/WT
K151
20
WT
K255
20
WT/DG
LOW
IDLE
POSITION
SWITCH
SUPPLY
5V
PEDAL
POSITION
SENSOR
POWERTRAIN
CONTROL
MODULE
SIGNAL
SENSOR
POSITION
THROTTLE
10
CONTROLLER
MSA
PEDAL
POSITION
SENSOR
SENSOR
POSITION
PEDAL
K22
20
OR/DB
K22
20
OR/DB
K22
20
OR/DB
K6
20
VT/WT
K151
20
WT
K255
20
WT/DG
1 2 3 4
12 11 10 9 C307
C182
8
SENSOR
GROUND
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
S211
F8 C234
S119
6 C131
S136
33
GROUND
SENSOR
(8W-33-4)
(8W-30-23)
(8W-70-8)
(8W-12-6)
(8W-70-4)
(8W-70-8)
8W - 31 - 6 8W-31 TRANSMISSION SYSTEM
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03105
8W-31 TRANSMISSION CONTROL SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
GOVERNOR PRESSURE SENSOR . . . . . . . . . . . 7
OUTPUT SHAFT SPEED SENSOR . . . . . . . . . . . 7
OVERDRIVE SWITCH . . . . . . . . . . . . . . . . . . . . . 7
SHIFT INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . 7
TRANSMISSION CONTROL RELAY . . . . . . . . . . 7
TRANSMISSION SOLENOID ASSEMBLY . . . . . . 7
TRANSMISSION TEMPERATURE SENSOR . . . . 8
DESCRIPTION AND OPERATION
OVERDRIVE SWITCH
Automati c transmi ssi on equi pped vehi cl es have an
overdri ve swi tch. The operator di sabl es or enabl es
overdri ve when the swi tch i s depressed.
The overdri ve system consi sts of a swi tch con-
nected to the Powertrai n Control Modul e (PCM) and
a Li ght Emi tti ng Di ode (LED) whi ch i l l umi nates for
the overdri ve ON/OFF i ndi cator.
I f overdri ve i s currentl y enabl ed, i t i s di sabl ed
when the operator depresses the overdri ve swi tch.
Al so, i f the operator al ready di sabl ed overdri ve, i t i s
enabl ed when the swi tch i s depressed.
Ci rcui t T9 from the overdri ve swi tch connects to
cavi ty C13 of the PCM and provi des the overdri ve
si gnal . Ci rcui t Z1 provi des ground for the swi tch.
I n the RUN posi ti on, the i gni ti on swi tch connects
ci rcui t A1 from fuse 8 i n the Power Di stri buti on Cen-
ter (PDC) wi th ci rcui t A22. Ci rcui t A22 powers ci rcui t
F71 through fuse 12 i n the juncti on bl ock. Ci rcui t
F71 suppl i es power for the overdri ve ON/OFF i ndi ca-
tor LED. The PCM turns the overdri ve ON/OFF i ndi -
cator ON or OFF by provi di ng ground on ci rcui t G68.
Ci rcui t G68 connects to cavi ty C6 of the PCM.
TRANSMISSION CONTROL RELAY
The transmi ssi on control rel ay powers the over-
dri ve sol enoi d, torque convertor cl utch sol enoi d, and
vari abl e force sol enoi d. Al l three sol enoi ds are
mol ded together.
When the i gni ti on swi tch i s i n the START or RUN
posi ti ons, i t connects ci rcui t A1 from fuse 8 i n the
Power Di stri buti on Center (PDC) to ci rcui t A21. Ci r-
cui t A21 powers ci rcui t F99 through fuse 18 i n the
PDC. Ci rcui t F99 powers the coi l si de of the el ec-
troni c transmi ssi on rel ay. The Powertrai n Control
Modul e (PCM) provi des ground for the rel ay on ci r-
cui t T66. Ci rcui t T66 connects to cavi ty B30 of the
PCM.
When the PCM grounds the rel ay, the rel ay con-
tacts connect ci rcui t F92 from fuse 17 i n the PDC to
ci rcui t T20. Ci rcui t T20 powers the sol enoi ds.
TRANSMISSION SOLENOID ASSEMBLY
The Torque Convertor Cl utch (TCC) sol enoi d, over-
dri ve sol enoi d and vari abl e force sol enoi d are mol ded
together. Ci rcui t T20 from the el ectroni c transmi s-
si on rel ay suppl i es power for the sol enoi ds. The Pow-
ertrai n Control Modul e (PCM) operates each sol enoi d
i ndi vi dual l y by provi di ng ground for each sol enoi d on
separate ci rcui ts.
The PCM provi des ground for the TCC sol enoi d
on ci rcui t T22. Ci rcui t T22 connects to cavi ty B11 of
the PCM.
The PCM suppl i es ground for the overdri ve sol e-
noi d on ci rcui t T60. Ci rcui t T60 connects to cavi ty
B21 of the PCM.
On ci rcui t T59, the PCM provi des ground for the
vari abl e force sol enoi d. Ci rcui t T59 connects to cavi ty
B8 of the PCM.
SHIFT INTERLOCK
The shi ft i nterl ock prevents the operator from
shi fti ng the vehi cl e out of PARK unl ess the brake
pedal i s pressed. When the i gni ti on swi tch i s i n the
START or RUN posi ti on, ci rcui t A21 feeds ci rcui t F87
through fuse 5 i n the juncti on bl ock. Ci rcui t F87
spl i ces to power the shi ft i nterl ock.
When the brake pedal i s not depressed, the stop
l amp swi tch provi des ground for i nterl ock by connect-
i ng ci rcui t L53 to ground. When grounded, the i nter-
l ock prevents shi fti ng the transmi ssi on out of PARK.
When the brake pedal i s pressed, the stop l amp
swi tch di sconnects ci rcui t L53 from ground.
OUTPUT SHAFT SPEED SENSOR
The output shaft speed sensor generates a si gnal
i ndi cati ng the speed of the transmi ssi on output shaft.
Ci rcui ts T13 and T14 connect the sensor to the Pow-
ertrai n Control Modul e (PCM). Ci rcui t T13 connects
to cavi ty B25 of the PCM. Ci rcui t T14 connects to
cavi ty B28.
GOVERNOR PRESSURE SENSOR
The governor pressure sensor suppl i es the trans-
mi ssi on pressure i nput to the Powertrai n Control
Modul e on ci rcui t T25. Ci rcui t T25 connects to cavi ty
ZG 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7
B29 of the PCM. Ci rcui t K6 from cavi ty B31 of the
PCM suppl i es 5 vol ts to the sensor. The PCM pro-
vi des ground for the govenor pressure sensor on ci r-
cui t K4. Ci rcui t K4 connects to cavi ty A4 of the PCM.
The governor pressure sensor i s part of the trans-
mi ssi on sol enoi d assembl y.
TRANSMISSION TEMPERATURE SENSOR
The transmi ssi on temperature sensor i s l ocated i n
the transmi ssi on sol enoi d assembl y. The Powertrai n
Control Modul e (PCM) suppl i es 5 vol ts to the sensor
on ci rcui t K6. Ci rcui t T54 from the sensor connects to
cavi ty B1 of the PCM and provi des the transmi ssi on
temperature i nput. The PCM provi des ground for the
sensor on cavi ty K4.
I f transmi ssi on temperature exceeds a cal i brated
temperature, the PCM sends a si gnal to the Vehi cl e
I nformati on Center (VI C) over the CCD bus. I n
response, the VI C di spl ays a message to the dri ver.
HELPFUL INFORMATION
Ci rcui t K6 al so suppl i es 5 vol ts to the vehi cl e speed
sensor.
Ci rcui t K4 al so provi des ground for the si gnal s
from the fol l owi ng:
Battery temperature sensor
Camshaft posi ti on sensor
Crankshaft posi ti on sensor
Downstream heated oxygen sensor
Engi ne cool ant temperature sensor
Fuel pump modul e
I ntake ai r temperature sensor
Mani fol d absol ute pressure sensor
Oi l pressure sensor
Powertrai n control modul e
Throttl e posi ti on sensor
Transmi ssi on sol enoi d assembl y
Upstream heated oxygen sensor
Vehi cl e speed control swi tch
Vehi cl e speed sensor
8W - 31 - 8 8W - 31 TRANSMISSION CONTROL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
8W-33 VEHICLE SPEED CONTROL
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Page
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3, 5
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2, 4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-4
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2, 4
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-33-2, 4
Left Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3, 5
MSA Control l er . . . . . . . . . . . . . . . . . . . . 8W-33-4, 5
Powertrai n Control Modul e . . . . . . . 8W-33-2, 3, 4, 5
Ri ght Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-33-3, 5
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3, 5
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-4
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
Component Page
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-5
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-5
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-5
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2, 4
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-5
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2, 4
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-33-2, 4
Vehi cl e Speed Control Servo . . . . . . . . . . . . 8W-33-2
Vehi cl e Speed Control /Horn Swi tch . . . . . 8W-33-3, 5
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . 8W-33-3, 5
ZG 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1
CONTROL
SOLENOID
VENT
CONTROL
SPEED SPEED
CONTROL
VACUUM
SOLENOID
CONTROL
SPEED
CONTROL
ON/OFF
SWITCH
SENSE
STOP
LAMP
SWITCH
SENSE
POWERTRAIN
CONTROL
MODULE
TN/RD
18
V36
LG/RD
18
V35
C234 F13
BR
20
L53
BR
18
L53
1
C3
C4
C3
C5
C3
C24
G107
S124
BK
10
Z4
BK
20
Z4
VEHICLE
SPEED
CONTROL
SERVO
GROUND
DB/LG
20
V30
1 2
4
3
4
YL/RD
18
V32
3
C3
C11
2
F9
V32
20
YL/RD
S206
L53
20
BR
8
C235
2
V30
20
DB/LG
Z1
20
BK
Z1
14
BK
S202
G304
2 C301
Z1
14
BK
SPEED
CONTROL
VACUUM
SOLENOID
CONTROL
SPEED
CONTROL
VENT
SOLENOID
CONTROL
SPEED
CONTROL
ON/OFF
SWITCH
OUTPUT
STOP
LAMP
SWITCH
5
6
15A
FUSE
9
C10
3
BATT A250
JUNCTION
BLOCK
L16
18
RD/LG
L50
18
WT/TN
L50
18
WT/TN
12
C305
S312
TO
9
(8W-70-5)
(8W-10-10)
(8W-12-2)
(8W-12-7)
(8W-15-18)
(8W-15-18)
(8W-31-5)
(8W-15-8)
(8W-15-8)
(8W-30-4)
(8W-30-10)
8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL
GAS ENGINES
ZG-RHD
J978W-3 ZGR03301
VEHICLE
SPEED
SENSOR
SIGNAL
5 VOLT
SUPPLY SIGNAL
SWITCH
CONTROL
SPEED
POWERTRAIN
CONTROL
MODULE
CLOCKSPRING
1
2 1 3 4 5
LEFT
SWITCH SWITCH
RIGHT
3 COAST
1 ON/OFF
2 SET ACC
VEHICLE
SPEED
CONTROL/
HORN
SWITCH
5 CANCEL
4 RES/ACC
C32
C3 C2
B31
S132
S131
B27
C2
3 1
5 VOLT
SUPPLY SIGNAL
VSS
SENSOR
SPEED
VEHICLE
C1
A4
SENSOR
GROUND
2
CLOCKSPRING
K6
18
VT/WT
K6
18
VT/WT
G7
18
WT/OR
G7
18
WT/OR
K95
18
PK
F19 C234
K95
20
PK
4.0L 5.2L
BK/LB
18
K4 K4
20
BK/LB
K4
18
BK/LB
F8 C234
S102
BK/LB
20
K4
BK/LB
20
K4
10 C131
BK/LB
18
K4
GROUND
SENSOR
BK/LB
18
K4
2
S135
(8W-30-17)
(8W-70-2)
(8W-70-2)
(8W-70-6)
(8W-70-3)
ZG-RHD 8W-33 VEHICLE SPEED CONTROL
GAS ENGINES
8W - 33 - 3
ZGR03302 J978W-3
SPEED
CONTROL
ON/OFF
SWITCH
SENSE
STOP
LAMP
SWITCH
SENSE
POWERTRAIN
CONTROL
MODULE
C132 1
BR
20
L53
BR
20
L53
1
C4
24
G109
S121
BK
12
Z2
BK
20
Z2
DB/LG
20
V30
4
YL/RD
20
V32
3
44
2
8
V32
20
YL/RD
L53
20
BR
G8
C235
G2
Z1
20
BK
Z1
14
BK
S202
G304
2 C301
Z1
14
BK
STOP
LAMP
SWITCH
CONTROLLER
MSA
F9 F13 C234
V32
20
YL/RD
6
5
9
FUSE
15A
BATT A250
JUNCTION
BLOCK
3 C10
L16
18
RD/LG
L50
18
WT/TN
L50
18
WT/TN
12
C305
9
TO
S312
(8W-15-8)
(8W-15-4)
(8W-15-5)
(8W-15-18)
(8W-15-18)
(8W-50-11)
(8W-12-7)
(8W-10-10)
(8W-12-2)
(8W-70-5)
(8W-30-29)
8W - 33 - 4 8W-33 VEHICLE SPEED CONTROL
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03303
VEHICLE
SPEED
SENSOR
SIGNAL SIGNAL
SWITCH
CONTROL
SPEED
CLOCKSPRING
1
2 1 3 4 5
LEFT
SWITCH SWITCH
RIGHT
3 COAST
1 ON/OFF
2 SET ACC
VEHICLE
SPEED
CONTROL/
HORN
SWITCH
5 CANCEL
4 RES/ACC
36 43 33
SENSOR
GROUND
2
CLOCKSPRING
K95
20
PK
4 C144
K95
20
PK
2
C4
4
MODULE
CONTROL
POWERTRAIN
CONTROLLER
MSA
6
C4 C4
47
1 3
S140 S141
G7
20
WT/OR
G7
20
WT/OR
G7
20
WT/OR
K7
20
OR
K167
20
BR/YL
K167
20
BR/YL
SENSOR
SPEED
VEHICLE
SENSOR
GROUND SUPPLY
5V
VEHICLE
SPEED
SENSOR
SIGNAL
SENSOR
GROUND SUPPLY
5V VEHICLE
SPEED
SENSOR
SIGNAL
C234 F19
K95
20
PK
K4
20
BK/LB
K4
20
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
S136
6 C131
S102
F8 C234
S211
(8W-30-24)
(8W-30-24)
(8W-30-24) (8W-70-9)
(8W-70-8)
(8W-70-9)
(8W-70-8)
ZG-RHD 8W-33 VEHICLE SPEED CONTROL
DIESEL ENGINE
8W - 33 - 5
ZGR03304 J978W-3
8W-33 VEHICLE SPEED CONTROL
DESCRIPTION AND OPERATION
VEHICLE SPEED CONTROL
The Powertrai n Control Modul e (PCM) operates
the vehi cl e speed control system. The vehi cl e speed
control swi tches are l ocated i n the steeri ng wheel .
Ci rcui t V32 from cavi ty C11 of the PCM connects
to ci rcui t V30 through the stop l amp swi tch. Ci rcui t
V30 powers the vehi cl e speed control servo.
Ci rcui t K95 from PCM cavi ty C32 connects to the
vehi cl e speed control swi tches. The swi tches are
wi red i n paral l el and each contai ns a separate resi s-
tor. The vol tage l evel present on ci rcui t K95 (at PCM
cavi ty C32) depends on whi ch speed control swi tch i s
sel ected. Ci rcui t K4 from PCM cavi ty A4 suppl i es
ground for the speed control swi tches.
When the ON/OFF swi tch i s open, the vol tage
l evel on ci rcui t K95 at PCM cavi ty C32 has a nomi -
nal val ue of 5.0 vol ts wi th a range from 4.8 to 5.0
vol ts.
When the ON/OFF swi tch cl oses, the vol tage
l evel on ci rcui t K95 at PCM cavi ty C32 has nomi nal
val ue of 1.51 vol ts wi th a range from 1.31 to 1.61
vol ts.
When the SET swi tch cl oses, the vol tage l evel on
ci rcui t K95 at PCM cavi ty C32 has nomi nal val ue of
3.8 vol ts wi th a range from 3.6 to 3.9 vol ts.
When the RESUME/ACCEL swi tch cl oses, the
vol tage l evel on ci rcui t K95 at PCM cavi ty C32 has
nomi nal val ue of 4.4 vol ts wi th a range from 4.2 to
4.5 vol ts.
When the COAST swi tch cl oses, the vol tage
l evel on ci rcui t K95 at PCM cavi ty C32 has nomi nal
val ue of 2.92 vol ts wi th a range from 2.72 to 3.02
vol ts.
When the CANCEL swi tch cl oses, the vol tage
l evel on ci rcui t K95 at PCM cavi ty C32 has i s 0.1
vol ts or l ess.
The PCM control s the vent and vacuum functi ons
of the vehi cl e speed control servo on ci rcui ts V35 and
V36. Dependi ng on the si gnal i t recei ves from vehi cl e
speed control swi tches, the PCM ei ther appl i es vac-
uum to or vents vacuum from the servo. Ci rcui t V36
from cavi ty C4 of the PCM sends the vacuum si gnal
to the servo. Ci rcui t V35 from cavi ty C5 sends the
vent si gnal .
Ci rcui t L53 provi des the stop l amp swi tch sense
i nput to the PCM at cavi ty C24. The stop l amp
swi tch connects ci rcui t L53 to ground on ci rcui t Z1.
When the brake pedal i s depressed, the stop l amp
swi tch opens and di sconnects ci rcui ts L53 and Z1,
and ci rcui ts V32 and V30. When the stop l amp
swi tch di sconnects ci rcui ts V32 and V30, power i s
removed from the speed control servo.
HELPFUL INFORMATION
Ci rcui t K4 al so provi des ground for some of the
engi ne control sensors that provi de i nputs to the
PCM.
VEHICLE SPEED CONTROL (DIESEL)
The Powertrai n Control Modul e (PCM) operates
the vehi cl e speed control system. The vehi cl e speed
control swi tches are l ocated i n the steeri ng wheel .
Ci rcui t V32 from the PCM connects to ci rcui t V30
through the stop l amp swi tch. Ci rcui t V30 connects
to ci rcui t Z2 ground. Ci rcui t L53 from the PCM con-
nects to Ci rcui t Z1 ground, through the stop l amp
swi tch.
Ci rcui t K95 from the PCM connects to the vehi cl e
speed control swi tches. The swi tches are wi red i n
paral l el and each contai ns a separate resi stor. The
vol tage l evel present on ci rcui t K95 at the PCM
depends on whi ch speed control swi tch i s sel ected.
Ci rcui t K4 from PCM suppl i es ground for the speed
control swi tches.
When the ON/OFF swi tch i s open, the vol tage
l evel on ci rcui t K95 at the PCM has a nomi nal val ue
of 5.0 vol ts wi th a range from 4.8 to 5.0 vol ts.
When the ON/OFF swi tch cl oses, the vol tage
l evel on ci rcui t K95 at the PCM has nomi nal val ue of
1.51 vol ts wi th a range from 1.31 to 1.61 vol ts.
When the SET swi tch cl oses, the vol tage l evel on
ci rcui t K95 at the PCM has nomi nal val ue of 3.8
vol ts wi th a range from 3.6 to 3.9 vol ts.
When the RESUME/ACCEL swi tch cl oses, the
vol tage l evel on ci rcui t K95 at the PCM has nomi nal
val ue of 4.4 vol ts wi th a range from 4.2 to 4.5 vol ts.
When the COAST swi tch cl oses, the vol tage
l evel on ci rcui t K95 at the PCM has nomi nal val ue of
2.92 vol ts wi th a range from 2.72 to 3.02 vol ts.
When the CANCEL swi tch cl oses, the vol tage
l evel on ci rcui t K95 at the PCM i s 0.1 vol ts or l ess.
Ci rcui t L53 and V32 provi de stop l amp swi tch
sense i nput to the PCM. When the brake pedal i s
depressed, the stop l amp swi tch opens and di scon-
nects ci rcui ts L53 and Z1, and ci rcui ts V32 and V30
i ndi cati ng brakes are appl i ed.
HELPFUL INFORMATION
Ci rcui t K4 al so provi des ground for some of the
engi ne control sensors that provi de i nputs to the
PCM.
8W - 33 - 6 8W - 33 VEHICLE SPEED CONTROL ZG
8W-35 ALL-WHEEL ANTI-LOCK BRAKES
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Page
Control l er Anti -Lock Brake . . . . . . . . . 8W-35-2, 3, 4
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
G Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-35-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
Left Front Wheel Speed Sensor . . . . . . . . . . 8W-35-4
Left Rear Wheel Speed Sensor . . . . . . . . . . 8W-35-4
Component Page
Power Di stri buti on Center . . . . . . . . . . . . . 8W-35-2
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-35-2
Ri ght Front Wheel Speed Sensor . . . . . . . . 8W-35-4
Ri ght Rear Wheel Speed Sensor . . . . . . . . . 8W-35-4
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Speed Proporti onal Steeri ng Modul e . . . . . . 8W-35-2
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-35-3
ZG 8W - 35 ALL-WHEEL ANTI-LOCK BRAKES 8W - 35 - 1
20
BRAKE
ANTI-LOCK
CONTROLLER
CENTER
DISTRIBUTION
POWER
27
14
FUSE
20A
20
9
A20
14
RD/LG RD/DB
10
A10
25
11
50A
FUSE
5
4
BATT A0
C3
11
23
10A
FUSE
11
F12
20
DB/WT
RUN A22
8 24
S125
Z2
12
BK
Z2
12
BK
Z2
12
BK
G108
D83
20
BK/PK
D83
20
BK/PK
FUSED
IGN.
(ST-RUN)
GROUND GROUND
FUSED
B (+)
FUSED
B (+)
JUNCTION
BLOCK
MODULE
STEERING
PROPORTIONAL
SPEED
S200
BK/PK
D83
20
2 C144
BK/PK
D83
20
SCI
RECEIVE
SCI
RECEIVE
12
S142
BK/PK
D83
20
BK/PK
20
D83
20 C1
BRAKE
ANTI-LOCK
CONTROLLER POWERTRAIN
25
MODULE
CONTROL
C3
(8W-30-2)
(8W-30-30)
(8W-30-2)
(8W-65-2)
(8W-10-3) (8W-10-8)
(8W-12-2)
(8W-15-8)
(8W-12-9) (8W-10-5) (8W-10-10)
(8W-10-3)
8W - 35 - 2 8W-35 ANTI-LOCK BRAKES ZG-RHD
J978W-3 ZGR03501
15A
FUSE
9
C10
3
BATT A250
JUNCTION
BLOCK
L16
18
RD/LG
5
6
L50
18
WT/TN
S312
L50
18
WT/TN
16 C304
L50
18
WT/TN
12
BRAKE
ANTI-LOCK
CONTROLLER
SWITCH
G
2 3
B43
20
PK/OR
8
B43
20
PK/OR
6 7
B41
20
YL/VT
6 C304 7
B41
20
YL/VT
B42
20
TN/WT
B42
20
TN/WT
ACCEL
SENSOR
NO. 1 NO. 2
SENSOR
ACCEL STOP
LAMP
SWITCH
OUTPUT
16
4
G5 C235
205
20
WT/VT
205
20
WT/VT
INSTRUMENT
CLUSTER
ABS
WARNING
LAMP
DRIVER
ABS
WARNING
LAMP
L50
18
WT/TN
12
C305
STOP
LAMP
SWITCH
SENSOR
GROUND
1
13
9
(8W-33-2)
(8W-10-10)
(8W-40-5)
(8W-70-5)
(8W-12-2)
(8W-12-7)
ZG-RHD 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3
ZGR03502 J978W-3
CONTROLLER
ANTI-LOCK
BRAKE
LEFT
FRONT
WHEEL
SPEED
SENSOR
11
LEFT
FRONT
WHEEL
SPEED
SENSOR
(+) (-)
SENSOR
SPEED
WHEEL
FRONT
LEFT
4
2 1
A B
10
LEFT
REAR
WHEEL
SPEED
SENSOR
(+) (-)
SENSOR
SPEED
WHEEL
REAR
LEFT
2
SENSOR
SPEED
WHEEL
REAR
LEFT
2 1
18
RIGHT
FRONT
WHEEL
SPEED
SENSOR
(-) (+)
SENSOR
SPEED
WHEEL
FRONT
RIGHT
3
SENSOR
SPEED
WHEEL
FRONT
RIGHT
A B
17
RIGHT
REAR
WHEEL
SPEED
SENSOR
(+) (-)
SENSOR
SPEED
WHEEL
REAR
RIGHT
1
SENSOR
SPEED
WHEEL
REAR
RIGHT
B8
20
RD/DB RD
20
B9
WT
20
B7
WT/DB
20
B6
B3
20
LG/DB
B3
20
LG/DB
12
C304
13
LG
20
B4
LG
20
B4
3
YL/DB
20
B1
YL/DB
20
B1
C304
4
YL
20
B2
YL
20
B2
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
8W - 35 - 4 8W-35 ANTI-LOCK BRAKES ZG-RHD
J978W-3 ZGR03503
8W-35 ALL-WHEEL ANTI-LOCK BRAKES
INDEX
page page
DESCRIPTION AND OPERATION
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . 5
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . 5
G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 5
STOP LAMP SWITCH INPUT . . . . . . . . . . . . . . . 5
WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . 5
DESCRIPTION AND OPERATION
INTRODUCTION
Several fuses suppl y power for the Anti -Lock Brake
System (ABS); fuses 5, 8, 11, and 14 i n the Power
Di stri buti on Center (PDC) and fuse 9 and 11 i n the
juncti on bl ock. Fuses 5, 8, 11, and 14 i n the PDC are
connected di rectl y to battery vol tage and are HOT al l
ti mes. Fuse 11 i n the juncti on bl ock i s HOT when the
i gni ti on swi tch i s i n the RUN posi ti on. Fuse 9 i n the
juncti on bl ock i s Hot at al l ti mes.
I n the RUN posi ti on, the i gni ti on swi tch connects
ci rcui t A1 from fuse 8 i n the PDC wi th ci rcui t A22.
Ci rcui t A22 feeds ci rcui t F12 through fuse 11 i n the
juncti on bl ock. Ci rcui t F12 connects to the Control l er,
Anti -Lock Brakes (CAB).
Ci rcui t Z2 provi des ground for the CAB.
Refer to group 5, Brakes for operati onal descri p-
ti ons of ABS system components.
WHEEL SPEED SENSORS
The al l wheel anti -l ock system uses four wheel
speed sensors; one for each wheel . Each sensor con-
verts wheel speed i nto an el ectri cal si gnal that i t
transmi ts to the Control l er, Anti -Lock Brakes (CAB).
A pai r of twi sted wi res connect to each sensor to pro-
vi de si gnal s to the CAB.
Ci rcui ts B6 and B7 provi de si gnal s to the CAB
from the ri ght front wheel speed sensor.
Ci rcui ts B8 and B9 provi de si gnal s to the CAB
from the l eft front wheel speed sensor.
Ci rcui ts B1 and B2 provi de si gnal s to the CAB
from ri ght rear wheel speed sensor.
Ci rcui ts B4 and B3 provi de si gnal s to the CAB
from the l eft rear wheel speed sensor.
G-SWITCH
Duri ng four-wheel dri ve operati on, the G-swi tch
provi des decel erati on data to the Control l er, Anti -
Lock Brakes (CAB). Refer to Group 5, Brakes for
addi ti onal i nformati on.
Ci rcui ts B41, B42, and B43 connect the G-swi tch to
the CAB. Ci rcui ts B41 and B42 provi de swi tch states
whi l e ci rcui t B43 provi des ground.
ABS WARNING LAMP
Ci rcui t F87 from fuse 5 i n the juncti on bl ock pro-
vi des power for the ABS warni ng l amp i n the i nstru-
ment cl uster. Ground for the ABS warni ng l amp i s
provi ded by the Control l er, Anti -Lock Brakes (CAB).
The CAB i l l umi nates the l amp by provi di ng ground
on ci rcui t 205.
HELPFUL INFORMATION
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from fuse 8 i n the
Power Di stri buti on Center (PDC) to ci rcui t A21. Ci r-
cui t A21 powers ci rcui t F87 through fuse 5 i n the
juncti on bl ock.
STOP LAMP SWITCH INPUT
Ci rcui t L50 from the stop l amp swi tch provi des the
brake swi tch i nput to the Control l er, Anti -Lock
Brakes (CAB). When the brake pedal i s depressed,
the stop l amp swi tch cl oses to suppl y battery vol tage
from ci rcui t L16 to ci rcui t L50. Ci rcui t L50 connects
to the CAB. Ci rcui t L16 ori gi nates at fuse 9 i n the
juncti on bl ock. Ci rcui t A250 from fuse 11 i n the
Power Di stri buti on Center (PDC) suppl i es power to
juncti on bl ock fuse 9.
DATA LINK CONNECTOR
Ci rcui t D83 from cavi ty A3 of the Control l er, Anti -
Lock Brakes (CAB) transmi ts data to the DRB scan
tool through the data l i nk connector. Through the
data l i nk connector, ci rcui ts Z1 and Z2 provi de
ground for the DRB scan tool .
Ci rcui t F75 suppl i es battery vol tage to the scan
tool through the di agnosti c connector.
ZG 8W - 35 ALL-WHEEL ANTI-LOCK BRAKES 8W - 35 - 5
8W-39 VEHICLE THEFT SECURITY SYSTEM
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Page
Automati c Headl amp Li ght
Sensor/Vtss Led . . . . . . . . . . . . . . . . . . . 8W-39-3
Body Control Modul e . . . . . . . . . . 8W-39-2, 3, 4, 5, 6
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
Engi ne Starter Motor Rel ay . . . . . . . . . . . . 8W-39-2
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4
Hood Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . 8W-39-2, 3, 6
Left Front Cyl i nder Lock Swi tch . . . . . . . . . 8W-39-5
Left Front Door Ajar Swi tch . . . . . . . . . . . . 8W-39-5
Component Page
Left Rear Door Ajar Swi tch . . . . . . . . . . . . . 8W-39-5
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . . 8W-39-4
Li ftgate Cyl i nder Lock Swi tch . . . . . . . . . . . 8W-39-5
Li ftgl ass Ajar Swi tch . . . . . . . . . . . . . . . . . . 8W-39-4
Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Power Di stri buti on Center . . . . . . . . . 8W-39-2, 3, 6
Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Ri ght Front Cyl i nder Lock Swi tch . . . . . . . . 8W-39-5
Ri ght Front Door Ajar Swi tch . . . . . . . . . . . 8W-39-5
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . . 8W-39-5
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4
S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4
Vehi cl e Speed Control /Horn Swi tch . . . . . . . 8W-39-6
ZG 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
8W-39 VEHICLE THEFT SECURITY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 7
VEHICLE THEFT SECURITY SYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION AND OPERATION
INTRODUCTION
The Body Control Modul e (BCM) operates the Vehi cl e
Theft Securi ty System (VTSS). The BCM moni tors the
vehi cl e doors, hood, l i ftgl ass i n the l i ftgate, l i ftgate, and
i gni ti on for unauthori zed operati on.
When the BCM detects unauthori zed operati on, i t oper-
ates the horn repeatedl y for three mi nutes and fl ashes the
headl amps and tai l l amps for 15 mi nutes. Al so, the engi ne
wi l l not operate unti l the VTSS i s di sarmed.
The vehi cl e operator can acti vate the al arm by pushi ng
the pani c button on the Remote Keyl ess Entry (RKE)
transmi tter. When the operator pushes the pani c button,
the radi o frequency recei ver i n the Passenger Door Modul e
(PDM) recei ves the PANI C si gnal and broadcasts a mes-
sage on the CCD bus. When the BCM sees the PANI C mes-
sage on the CCD bus, i t operates the horn repeatedl y, turns
on the i nteri or l i ghts, and fl ashes the headl amps and tai l
l amps. The BCM acti vates the pani c al arm for three mi n-
utes unl ess the operator starts the vehi cl e and dri ves at a
speed above 15 MPH or pushes the pani c button on the
RKE transmi tter a second ti me.
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from fuse 8 i n the
PDC to ci rcui t A21. Ci rcui t A21 powers ci rcui t F99
through PDC fuse 18. Ci rcui t F99 feeds the BCM.
I n the ACCESSORY or RUN posi ti on, the i gni ti on
swi tch connects ci rcui t A1 to ci rcui t A31. Ci rcui t A31
powers ci rcui t V23 through fuse 3 i n the juncti on
bl ock. Ci rcui t V23 feeds the BCM.
VEHICLE THEFT SECURITY SYSTEM OPERATION
Each door, the l i ftgate, hood, and the l i ftgl ass i n
the l i ftgate have an ajar swi tch that connects to the
Body Control Modul e (BCM). The ajar swi tches are
normal l y open when the doors, l i ftgate, l i ftgl ass and
hood are cl osed. When one of them open, i ts ajar
swi tch cl oses and connects the BCM to ground. I n
response, i f the Vehi cl e Theft Securi ty System i s
armed, the BCM starts the al arm. Refer to the I ntro-
ducti on i n thi s secti on for al arm i nformati on.
The BCM recei ves the ajar swi tch si gnal s on the
fol l owi ng ci rcui ts.
Ci rcui t G75 provi des the l eft front door ajar
swi tch si gnal
Ci rcui t G74 provi des the ri ght front door ajar
swi tch si gnal
Ci rcui t G77 provi des the l eft rear door ajar
swi tch si gnal
Ci rcui t G76 provi des the ri ght rear door ajar
swi tch si gnal
Ci rcui t G78 provi des the l i ftgate ajar and l i ft-
gl ass ajar si gnal s
SYSTEM ARMING
The system al arm sets after the operator uses the power
door l ocks or Remote Keyl ess Entry (RKE) transmi tter to
l ock the doors and l i ftgate. After al l doors and the l i ftgate
are l ocked and cl osed, the BCM i l l umi nates a red Li ght
Emi tti ng Di ode (LED) (VTSS i ndi cator l i ght) on ci rcui t
G69. The red LED i s l ocated on the top of the i nstrument
panel . The LED fl ashes rapi dl y si gnal l i ng the system i s
armi ng. I t fl ashes at sl ower rate after approxi matel y 15
seconds, i ndi cati ng the BCM has set the VTSS.
SYSTEM DISARMING
The operator can di sarm the system by unl ocki ng a
front door or the l i ftgate wi th the key or the RKE
transmi tter. The BCM moni tors the l ock cyl i nder
swi tch i n each front door and the l i ftgate l ock cyl i n-
der swi tches on ci rcui t G71.
HORNS
When the BCM acti vates the horns, i t energi zes
the horn rel ay by provi di ng a ground path for the
rel ay coi l on ci rcui t X4. Ci rcui t F31 from fuse 6 i n
the Power Di stri buti on Center (PDC) powers the coi l
and contact si des of the rel ay.
When the horn rel ay energi ze, i ts contact cl ose and
connect ci rcui t F31 to ci rcui t X2. Ci rcui t X2 feeds the
horns. Ci rcui t Z1 provi des ground for the horns.
PARKING LAMPS
The BCM operates the park l amps when i t senses unau-
thori zed entry to the vehi cl e whi l e the Vehi cl e Theft Secu-
ri ty System i s armed. When i t senses unauthori zed entry,
the BCM energi zes the park l amp rel ay by provi di ng
ground for the rel ay coi l on ci rcui t L79. Ci rcui t 366 powers
the rel ay coi l and contacts. When the rel ay energi zes, i t
connects ci rcui t 366 to ci rcui t L90. Ci rcui t L90 powers the
park l amps, si de marker l amps and tai l l amps.
ZG 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 7
8W-40 INSTRUMENT CLUSTER
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Page
ABS Warni ng Lamp . . . . . . . . . . . . . . . . . . 8W-40-5
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-40-3
Ai rbag Warni ng Lamp . . . . . . . . . . . . . . . . . 8W-40-2
Body Control Modul e . . . . . . . . . . . . . . 8W-40-3, 4, 6
Brake Warni ng Lamp . . . . . . . . . . . . . . . . . 8W-40-5
Brake Warni ng Swi tch . . . . . . . . . . . . . . . . 8W-40-6
Check Engi ne Lamp . . . . . . . . . . . . . . . . . . 8W-40-2
Check Gages Lamp . . . . . . . . . . . . . . . . . . . 8W-40-5
Control l er Anti -Lock Brake . . . . . . . . . . . . . 8W-40-5
Crui se Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
Engi ne Cool ant Temperature . . . . . . . . . . . 8W-40-3
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 5
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 5
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-40-4
Hi gh Beam I ndi cator Lamp . . . . . . . . . . . . . 8W-40-5
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-40-6
I l l umi nati on Lamps . . . . . . . . . . . . . . . . . . . 8W-40-4
I nstrument Cl uster . . . . . . . . . . . . . 8W-40-2, 3, 4, 5
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . 8W-40-2, 4, 5
Left Front Turn Si gnal Lamp . . . . . . . . . . . 8W-40-4
Left Turn Si gnal I ndi cator Lamp . . . . . . . . 8W-40-4
Component Page
Low Fuel Warni ng Lamp . . . . . . . . . . . . . . . 8W-40-2
Oi l Pressure Gauge . . . . . . . . . . . . . . . . . . . 8W-40-3
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-40-3
Ri ght Turn Si gnal I ndi cator Lamp . . . . . . . 8W-40-4
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
S149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 5
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 5
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 5
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 5
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 5
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
S409 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4
Seat Bel t Warni ng Lamp . . . . . . . . . . . . . . . 8W-40-2
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Turn Si gnal /Hazard Warni ng Swi tch . . . . . . 8W-40-4
Vol t Meter . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
ZG 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1
F75
18
VT
8
C4
20A
FUSE
7
JUNCTION
BLOCK
BATT A250
S201
F75
18
VT
3
AIRBAG
WARNING
LAMP
SEAT
BELT
WARNING
LAMP LAMP
WARNING
FUEL
LOW
LAMP
ENGINE
CHECK
FUSED
B(+)
GROUND
1 2
Z1
20
BK
S216
Z1
16
BK
S202
Z1
14
BK
2 C301
Z1
14
BK
BK/OR
18
Z2
S205
BK/OR
20
Z2
8 C307
Z2
18
BK/OR
S302
Z2
18
BK/OR
G304
INSTRUMENT
CLUSTER
(8W-10-10)
(8W-12-8)
(8W-12-2)
(8W-12-8)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-15-18)
(8W-15-18)
8W - 40 - 2 8W-40 INSTRUMENT CLUSTER ZG-RHD
J978W-3 ZGR04001
CLUSTER
INSTRUMENT
19 18
CCD
BUS
(+) (-)
BUS
CCD
D1
18
VT/BR
AIRBAG
CONTROL
MODULE
SPEEDOMETER
SPEEDOMETER
CONTROL CONTROL
TACHOMETER
TACHOMETER
ENGINE COOLANT
TEMPERATURE
GAUGE
GAUGE CONTROL
ENGINE COOLANT
TEMPERATURE PRESSURE
OIL
GAUGE
GAUGE
PRESSURE
OIL
VOLT
METER
VOLT
METER
FUEL
GAUGE
FUEL
GAUGE
CCD
BUS
(+) (-)
BUS
CCD
8 9
D1
18
VT/BR
1
VT/BR
18
D1
VT/BR
18
D1
S306 S307
S204
D2
18
WT/BK
D2
18
WT/BK
C302 2
WT/BK
18
D2
WT/BK
18
D2
WT/BK
18
D2 D1
18
VT/BR
MODULE
CONTROL
BODY
CCD
BUS
(-) (+)
BUS
CCD
19 20
CCD
BUS
(+) (-)
BUS
CCD
POWERTRAIN
CONTROL
MODULE
D1
18
VT/BR
19
VT/BR
18
D1 D2
18
WT/BK
C235 20
WT/BK
18
D2
10 11
C30 C3 C28 C3
S203
C1 C1
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
C132 5 4
(8W-30-18)
(8W-30-31)
(8W-30-18)
(8W-30-19)
(8W-30-31)
(8W-30-32)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-43-3)
ZG-RHD 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3
ZGR04002 J978W-3
INSTRUMENT
CLUSTER
SWITCH
HEADLAMP
1
C2
16
BODY
CONTROL
MODULE
E2
20
OR
E2
20
OR
S209
E2
20
OR
10
LAMPS
ILLUMINATION
LAMP
INDICATOR
SIGNAL
TURN
LEFT RIGHT
TURN
SIGNAL
INDICATOR
LAMP
LG/DB
18
L65
6
16
WARNING
HAZARD
SIGNAL/
TURN
L65
18
LG/DB
F10 C234
L65
18
LG/DB
1 C102
L64
18
TN/DB
S409
L64
18
TN/DB
A
G
Z1
18
BK
S149
Z1
18
BK
3 C102
Z1
18
BK
G106
1
7
L64
18
TN/DB
BLOCK
JUNCTION
1
L64
18
TN/DB
GROUND
LEFT
TURN
SIGNAL
LAMP
C4
C4
SWITCH
11
FRONT
S109
16
BK
Z1
(8W-15-4)
(8W-15-5)
(8W-52-2)
(8W-12-2)
(8W-15-6)
(8W-15-7)
(8W-15-4)
(8W-15-5)
(8W-44-11)
(8W-45-10)
(8W-50-5)
8W - 40 - 4 8W-40 INSTRUMENT CLUSTER ZG-RHD
J978W-3 ZGR04003
F75
18
VT
8
C4
20A
FUSE
7
BATT A250
S201
F75
18
VT
3
BRAKE
WARNING
LAMP
HIGH
BEAM
INDICATOR
LAMP
LAMP
CRUISE
LAMP
GAGES
CHECK
FUSED
B(+)
GROUND
1 2
Z1
20
BK
S216
Z1
16
BK
S202
Z1
14
BK
2 C301
Z1
14
BK
BK/OR
18
Z2
S205
BK/OR
20
Z2
8 C307
Z2
18
BK/OR
S302
Z2
18
BK/OR
G304
5
FUSE
10A
BLOCK
JUNCTION
8
C9
F87
20
BK/WT
S215
F87
20
BK/WT
5
ABS
WARNING
LAMP
205
20
WT/VT
C235 5
VT/WT
20
205
4
16
BRAKE
ANTI-LOCK
CONTROLLER
DRIVER
LAMP
WARNING
ABS
ST-RUN A21
CLUSTER
INSTRUMENT
F87
20
BK/WT
GAS DIESEL
(8W-10-8)
(8W-35-3)
(8W-12-5)
(8W-12-2)
(8W-12-5)
(8W-15-18)
(8W-15-18)
(8W-15-18)
(8W-15-18)
(8W-15-17)
(8W-12-8)
(8W-12-8)
(8W-10-10)
ZG-RHD 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
ZGR04004 J978W-3
3
G9
18
GY/BK
F5 C234
GY/BK
16
G9
SWITCH
WARNING
BRAKE
G9
16
GY/BK
GAS OTHERS
2 C304
G9
20
GY/BK
S303
G9
20
GY/BK
2
C3
BRAKE
SWITCH
SENSE
BODY
CONTROL
MODULE
3
0 2
1
IGNITION
SWITCH
1 START
2 RUN
0 OFF
3 ACC
2
1
GY/BK
20
G9
(8W-10-7)
(8W-45-9)
(8W-45-9)
(8W-50-4)
8W - 40 - 6 8W-40 INSTRUMENT CLUSTER ZG-RHD
J978W-3 ZGR04005
8W-40 INSTRUMENT CLUSTER
INDEX
page page
DESCRIPTION AND OPERATION
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . 7
ENGINE COOLANT TEMPERATURE GAUGE . . . 7
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HIGH BEAM INDICATOR LAMP . . . . . . . . . . . . . . 8
ILLUMINATION LAMPS . . . . . . . . . . . . . . . . . . . . 8
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 7
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . 7
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 7
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TURN SIGNAL INDICATOR LAMPS . . . . . . . . . . . 8
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WARNING LAMPSEXCEPT ABS . . . . . . . . . . . 7
DESCRIPTION AND OPERATION
INTRODUCTION
The el ectroni c i nstrument cl uster contai ns a mi cro-
processor whi ch control s cl uster functi ons based on
data i t recei ves from the CCD bus. Ci rcui t A250 from
fuse 11 i n the Power Di stri buti on Center (PDC) pow-
ers ci rcui t F75 through fuse 7 i n the juncti on bl ock.
Ci rcui t F75 powers the cl uster mi cro-processor pl us
the warni ng l amps (except the ABS warni ng l amp)
and the hi gh beam i ndi cator l amp. The cl uster mi cro-
processor swi tches the warni ng l amps and hi gh beam
i ndi cator l amps on and off by control l i ng a transi stor
i n the ground path for each l amp.
WARNING LAMPS EXCEPT ABS
Ci rcui t F75 feeds al l the warni ng l amps i n the
i nstrument cl uster except the ABS wari ng l amp. The
mi cro-processor i n the cl uster control s each l amp
(except the ABS l amp) through a transi stor i n the
ground path of each l amp. The cl uster mi cro-proces-
sor turns the warni ng l amps ON and OFF based on
i nputs recei ved on the CCD bus. Ci rcui ts Z1 and Z2
provi de ground for the l amps and mi cro-processor.
SPEEDOMETER
The mi cro-processor i n the i nstrument cl uster cal -
cul ates the posi ti on of the speedometer needl e based
on the vehi cl e speed si gnal broadcast on the CCD bus
by the Powertrai n Control Modul e. The PCM deter-
mi nes vehi cl e speed from the i nput provi ded by the
vehi cl e speed sensor.
TACHOMETER
The Powertrai n Control Modul e (PCM) transmi ts
the engi ne RPM data on the CCD bus. From the bus,
the i nstrument cl uster cal cul ates tachometer needl e
posi ti on based on the engi ne RPM si gnal .
VOLTMETER
The Powertrai n Control Modul e (PCM) broadcasts
system vol tage data on the CCD bus. The mi cro-pro-
cessor i n the i nstrument cl uster cal cul ate vol tmeter
needl e posi ti on base on the si gnal recei ved from the
CCD bus.
FUEL GAUGE
The Powertrai n Control Modul e (PCM) transmi ts
the fuel percentage data over the CCD bus. The
mi cro-processor i n the i nstrument cl uster cal cul ates
posi ti on of the fuel gauge needl e based on the si gnal
from the PCM.
ENGINE COOLANT TEMPERATURE GAUGE
The Powertrai n Control Modul e (PCM) broadcasts
the engi ne cool ant temperature data over the CCD
bus. From the data si gnal on the CCD bus, the
i nstrument cl uster mi cro-processor cal cul ates cool ant
temperature gauge needl e posi ti on.
ABS WARNING LAMP
Ci rcui t F87 from fuse 5 i n the juncti on bl ock pro-
vi des power for the ABS warni ng l amp i n the i nstru-
ment cl uster. Ground for the ABS warni ng l amp i s
provi ded by the Control l er, Anti -Lock Brakes (CAB).
The CAB i l l umi nates the l amp by provi di ng ground
on ci rcui t 205.
HELPFUL INFORMATION
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from fuse 8 i n the
Power Di stri buti on Center (PDC) to ci rcui t A21. Ci r-
cui t A21 powers ci rcui t F87 through fuse 5 i n the
juncti on bl ock.
OIL PRESSURE GAUGE
The i nstrument cl uster mi cro-processor cal cul ates
engi ne oi l pressure gauge needl e posi ti on based on
the oi l pressure data recei ved over the CCD bus. The
ZG 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 7
Powertrai n Control Modul e (PCM) transmi ts the
data over the CCD bus.
HIGH BEAM INDICATOR LAMP
The mi cro-processor i n the i nstrument cl uster
swi tches the hi gh beam i ndi cator l amp ON and OFF
through a transi stor i n l amps ground ci rcui t. The
Body Control Modul e (BCM) si gnal s the i nstrument
cl uster mi cro-processor over the CCD bus to turn the
hi gh beam i ndi cator ON or OFF. Ci rcui t F75 powers
the l amp.
TURN SIGNAL INDICATOR LAMPS
Ci rcui ts L65 and L64 from the turn si gnal /hazard
fl asher ci rcui try i n the mul ti -functi on swi tch power
the turn si gnal i ndi cator l amps. Ci rcui t L64 powers
the ri ght turn si gnal i ndi cator l amp. Ci rcui t L65
powers the l eft i ndi cator l amp. Ci rcui ts Z1 and Z2
provi de ground for the l amps.
ILLUMINATION LAMPS
Ci rcui t E2 from the headl amp swi tch powers the
i l l umi nati on l amps i n the i nstrument cl uster. Ci r-
cui ts Z1 and Z2 provi de ground for the l amps.
8W - 40 - 8 8W - 40 INSTRUMENT CLUSTER ZG
DESCRIPTION AND OPERATION (Continued)
8W-41 HORN/CIGAR LIGHTER
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Page
Body Control Modul e . . . . . . . . . . . . . . . . . . 8W-41-2
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . 8W-41-3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Component Page
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Power Di stri buti on Center . . . . . . . . . . . . . 8W-41-2
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Vehi cl e Speed Control /Horn Swi tch . . . . . . . 8W-41-2
ZG 8W - 41 HORN/CIGAR LIGHTER 8W - 41 - 1
6
FUSE
20A
BATT A0
POWER
DISTRIBUTION
CENTER
5
12
F31
16
VT
X2
16
DG/YL
S106
X2
16
DG/YL
X2
16
DG/YL
1 1
2 2
NO. 2
HORN HORN
NO. 1
Z1
16
BK
Z1
16
BK
S104
Z1
14
BK
G106
X4
20
GY/OR
1 C1
BLOCK
JUNCTION
SWITCH
HORN
CONTROL/
SPEED
VEHICLE
5
BODY
CONTROL
MODULE
HORN
RELAY
CONTROL
13 C2
7
C10 C7
12
X4
20
GY/OR
X4
20
GY/OR
CLOCKSPRING
HORN
SWITCH
F31 16 VT
HORN
RELAY
A3 A1
A5 A2
(8W-45-3)
(8W-45-3)
(8W-12-2)
(8W-15-6)
(8W-15-7)
(8W-15-6)
(8W-15-7)
(8W-10-3)
(8W-10-3)
(8W-10-5)
8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET ZG-RHD
J978W-3 ZGR04101
F38
18
OR
1
85 87
30 86
RD/BK
18
A31
OUTLET
POWER
C4
3
C4 4
CIGAR
LIGHTER
RELAY
9
C7
CIGAR
LIGHTER
1
2 2
Z1
18
BK
F30
18
RD/DB
Z1
18
BK
Z1
18
BK
S220
G304
Z1
16
BK
BLOCK
JUNCTION
S216
Z1
16
BK
S202
Z1
14
BK
2 C301
Z1
14
BK
15A
FUSE
21 14
FUSE
15A
2
C9
BLOCK
JUNCTION
C10
9
NO
CONNECTION
2
FUSE
15A
C7
4
RUN-ACC A31 BATT F61 BATT A7 (8W-10-12) (8W-10-9) (8W-10-9)
(8W-12-3)
(8W-12-2)
(8W-12-3) (8W-12-16)
(8W-15-18)
(8W-15-17)
(8W-12-2)
(8W-15-18)
(8W-15-17)
ZG-RHD 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3
ZGR04102 J978W-3
8W-41 HORN/CIGAR LIGHTER
DESCRIPTION AND OPERATION
HORN
The horn system i s powered by ci rcui t F31 from
fuse 6 i n the Power Di stri buti on Center (PDC). Ci r-
cui t F31 suppl i es vol tage to the coi l and contact si des
of the horn rel ay i n the PDC.
When the operator presses the horn swi tch, a
ground path i s compl eted on the coi l si de of the horn
rel ay through the case grounded swi tch, on ci rcui t
X4. The horn rel ay contacts then cl oses to connect
ci rcui t F31 to ci rcui t X2. Ci rcui t X2 powers the
horns. Ci rcui t Z1 provi des ground for the horns.
On vehi cl es equi pped wi th Vehi cl e Theft Securi ty
System (VTSS), the X4 ci rcui t i s spl i ced to the Body
Control Modul e (BCM). For operati on of the VTSS,
refer to secti on 8W-39.
CIGAR LIGHTER
The ci gar l i ghter rel ay powers the ci gar l i ghter.
The rel ay energi zes when the i gni ti on swi tch i s i n
the ACCESSORY or RUN posi ti on. I n the ACCES-
SORY or RUN posi ti on, the swi tch connects ci rcui t
A1 from fuse 8 i n the Power Di stri buti on Center
(PDC) to ci rcui t A31. Ci rcui t A31 powers rel ay coi l .
Ci rcui t Z1 provi des ground for the rel ay coi l .
When the rel ay energi zes, i ts connects ci rcui t F61
from fuse 10 i n the PDC to ci rcui t F30. Ci rcui t F30
powers the ci gar l i ghter.
When the operator depresses the l i ghter, contacts
i nsi de the l i ghter el ement cl ose, and vol tage from ci r-
cui t F30 fl ows through the heati ng el ement to
ground. Ci rcui t Z1 provi des ground for the l i ghter.
HELPFUL INFORMATION
Ci rcui t Z1 al so grounds the power outl et.
POWER OUTLET
Ci rcui t A7 from 15 i n the Power Di stri buti on Cen-
ter (PDC) powers ci rcui t F38 through fuse 21 i n the
juncti on bl ock. Ci rcui t F38 feeds the power outl et.
Ci rcui ts A7 and F38 are HOT at al l ti mes. Ci rcui t Z1
provi des ground for the power outl et.
8W - 41 - 4 8W - 41 HORN/CIGAR LIGHTER ZG
8W-42 AIR CONDITIONING/HEATER
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . 8W-42-10, 11
A/C Compressor Cl utch Rel ay . . . . . . . 8W-42-10, 11
A/C Heater Control . . . . . . . . . . . . . . . . . 8W-42-2, 5
A/C Hi gh Pressure Swi tch . . . . . . . . . . 8W-42-12, 13
A/C Low Pressure Swi tch . . . . . . . . . . 8W-42-12, 13
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-42-6
Automati c Shut Down Rel ay . . . . . . . . . . . 8W-42-11
Automati c Temperature Control
Modul e . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 6, 8, 9
Bl end Door Actuator . . . . . . . . . . . . . . 8W-42-6, 7, 8
Bl ower Motor . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 5
Bl ower Motor Resi ster Bl ock . . . . . . . . . . 8W-42-2, 5
Bl ower Power Modul e . . . . . . . . . . . . . . . . . 8W-42-3
Body Control Modul e . . . . . . . . . . . . . . 8W-42-4, 5, 6
Data Li nk Connector . . . . . . . . . . . . . . . . . . 8W-42-9
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-11
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5, 7, 9
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-10
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 11
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-10, 11
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-12
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 4, 7
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
Hi gh Speed Bl ower Motor Rel ay . . . . . . . . . 8W-42-3
I n-Car Temperature Sensor . . . . . . . . . . . . . 8W-42-6
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-42-2, 5, 7, 9
Mode Door Actuator . . . . . . . . . . . . . . . . 8W-42-6, 8
MSA Control l er . . . . . . . . . . . . . . . . . . . . . 8W-42-13
Power Di stri buti on Center . . . . . . 8W-42-2, 3, 10, 11
Powertrai n Control Modul e . . . . . . . . . 8W-42-12, 13
Reci rcul ati on Door Actuator . . . . . . . . . . . . 8W-42-9
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-10
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-12
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 4, 7
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-4, 6
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-4, 6
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7, 9
S219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 8
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 5
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 8
S223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8
S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
S225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
S226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 4
Sol ar Sensor . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6
ZG 8W - 42 AIR CONDITIONING/HEATER 8W - 42 - 1
20
FUSE
15A
BATT A7
JUNCTION
BLOCK
C9 12
D7
C13
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
FUSED
B (+)
GROUND
F60
20
WT/RD
Z4
20
PK
Z4
20
BK
Z4
12
BK
Z4
12
BK
Z4
10
BK
G107
S124
S226
2 C160
P C206
6
BATT A0
40A
FUSE
7
13
CENTER
DISTRIBUTION
POWER
A19
12
RD/VT
A19
12
RD
1 C160
1
2
A/C HEATER)
(MANUAL
MOTOR
BLOWER
C7
12
BK
S221
3 3
A/C
HEATER
CONTROL
C7
12
BK
C7
12
BK/TN
C7
12
BK/TN
B C206
BLOWER
MOTOR
SWITCH
M
C1
BLOCK
RESISTOR
MOTOR
BLOWER
(8W-42-5)
(8W-10-3)
(8W-10-6)
(8W-10-3)
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-12-2)
(8W-10-12)
(8W-12-16)
(8W-42-5)
8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER ZG-RHD
J978W-3 ZGR04201
7
FUSE
40A
BATT A0
6
13
A19
12
RD/VT
A19
10
RD
1 C160
A19
14
RD/VT
A19
12
DG/RD
A19
10
RD
S225
5 1
2 4
HIGH
SPEED
BLOWER
MOTOR
RELAY
3
4
1
MODULE
POWER
BLOWER
C42
12
BR/RD
C42
12
BR/RD
D5 D2
S224
HIGH
SPEED
BLOWER
MOTOR
RELAY
OUTPUT SIGNAL
RELAY
MOTOR
BLOWER
SPEED
HIGH
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
C42
12
BR/RD
C42
18
PK/DB
C41
20
BR
C41
20
GY/DB
M L C206
1
2
BLOWER
MOTOR
C42
12
RD
5
A
(8W-42-4)
B
(8W-42-4)
C
(8W-42-4)
TO
S226
TO
S226
TO
C206
C43
18
BR/YL
Z4
18
BK
Z4
12
BK
CENTER
DISTRIBUTION
POWER
BLOWER
MOTOR
DRIVER
FUSED
B (+)
OUTPUT GROUND
M
(8W-10-3)
(8W-10-3)
(8W-10-6)
ZG-RHD 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
ZGR04202 J978W-3
A
(8W-42-3)
B
(8W-42-3)
C
(8W-42-3)
Z4
18
BK
Z4
12
BK
S226
Z4
12
BK
Z4
20
BK
Z4
12
BK
Z4
20
PK
Z4
10
BK
C43
18
YL/BR
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
C9
BLOWER
POWER
MODULE
OUTPUT
G107
S124
GROUND
D7
AUTOMATIC
TEMPERATURE
CONTROL
MODULE
2 C160 P C206
A/C
SELECT
INPUT
C6
C2 7
C90
20
LG
MODULE
CONTROL
BODY
A/C
SELECT
INPUT
N C206
FROM
MODULE
MOTOR
BLOWER
C43
18
BR/YL
BLOWER
MOTOR
FROM
MODULE
MOTOR
BLOWER
FROM
LAMP
PANEL
D13
PANEL
DRIVER
LAMP
16 C2
E2
OR
20
S214
S209
OR
E2
20
OR
20
E2
(8W-44-11)
(8W-44-12)
(8W-44-11)
(8W-45-9)
(8W-15-8)
(8W-15-8)
8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER ZG-RHD
J978W-3 ZGR04203
C2
2
C2
3
C1
4
C1 1 C1 2 C1 5 3 C1
11 A/C ON
6
7
8
9
0 0 9
8
7
6
A/C
SWITCH
ILLUM.
BLOWER
SWITCH
ILLUM.
MODE
SWITCH
ILLUM.
A/C
HEATER
CONTROL
ILLUM.
MODE SWITCH
BLOWER SWITCH
A/C
SWITCH
10 11
A/C
HEATER
CONTROL
1 DEFROST
2 MIX
3 HEAT
4 BI-LEVEL
5 PANEL
0 OFF
6 LOW
7 MED-LOW
8 MED-HIGH
9 HIGH
10 A/C OFF
4
C2
6 C2
12
FUSE
10A
RUN A22
JUNCTION
BLOCK
C9 4
F71
20
DG/PK
1 4 2 3
BLOCK
RESISTOR
MOTOR
BLOWER
C4
14
TN
C4
14
TN
C5
14
LG
C5
14
LG
C6
14
LB
C6
14
LB
C7
12
BK
C7
12
BK/TN
C7
12
BK/TN
E C206 B D C
S221
2
MOTOR
BLOWER
C7
12
BK
C2 7
C90
20
LG
A/C
SELECT
INPUT
D
(8W-42-6)
TO
S214
E2
20
OR
C1
14
DG
C34
20
VT/WT
C36
20
DB/RD
F
(8W-42-7)
G
(8W-42-7)
H
(8W-42-7)
TO
C206
TO
S220
TO
C206
7
C2
HEATER)
A/C
(MANUAL
MODULE
CONTROL
BODY
4
3
2
1 5
(8W-12-10)
(8W-10-8)
(8W-12-2)
(8W-42-2)
(8W-42-3)
(8W-45-9)
ZG-RHD 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5
ZGR04204 J978W-3
D12 D15
IN-CAR
TEMPERATURE
SENSOR
SIGNAL SIGNAL
SENSOR
SOLAR
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
SENSOR
TEMPERATURE
IN-CAR SOLAR
SENSOR
B
A
B
A
C10
20
RD/TN
C47
20
BK/WT
D41
20
LG/WT
D41
20
LG/WT
D41
20
LG/WT
D41
20
LG/WT
C8
20
DG/RD
C8
20
DG/RD
D41
20
LG/WT
1
2
TEMPERATURE
AMBIENT
11
C235
19
F11 C234
C1 5 2 C1
AMBIENT
TEMPERATURE
SENSOR
SIGNAL
RETURN
SENSOR
BODY
CONTROL
MODULE
D13
DRIVER
LAMP
PANEL
16 C2
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
E2
20
OR
E2
20
OR
E2
20
OR
S209
S214
D
(8W-42-5)
E2
20
DR
FROM
CONTROL
HEATER
A/C
PANEL
LAMP
DRIVER
S219
LG/WT
20
D41 D41
20
LG/WT
D9
GROUND
SENSOR
S C206
D41
20
LG/WT
D41
20
LG/WT
3
MODE
DOOR
ACTUATOR
D41
20
LG/WT
3
(ATC)
ACTUATOR
DOOR
BLEND
S222
SENSOR
SENSOR
GROUND
(8W-42-7)
(8W-42-8)
(8W-42-8)
(8W-44-12)
(8W-44-11)
(8W-45-10)
8W - 42 - 6 8W-42 AIR CONDITIONING-HEATER
ATC
ZG-RHD
J978W-3 ZGR04205
9 C9
BLOCK
JUNCTION
RUN A22
10A
FUSE
12
G107
C1
14
DG
Z4
12
BK
Z4
12
BK
Z4
10
BK
J
2 C160
S124
C34
20
VT/WT
S220
Z1
16
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
2 C301
S202
S216
G304
4
1
C34
20
VT/WT
C34
20
VT/WT
H C206
BLEND
DOOR
ACTUATOR
3
C36
20
DB/RD
C36
20
DB/RD
F C206
2
C40
20
WT/YL
F71
20
PK/DG
F71
20
PK/DG
S218
F71
20
PK/DG
G C206
F
(8W-42-5)
G
(8W-42-5)
H
(8W-42-5)
FROM
CONTROL
HEATER
A/C A/C
HEATER
CONTROL
FROM FROM
CONTROL
HEATER
A/C
C206
FUSED
IGN.
(RUN)
BLEND
AIR
DOOR
POSITION
SWITCH
SIGNAL
COMMON
DOOR
NOT
USED
(8W-12-2)
(8W-10-8)
(8W-12-10)
(8W-15-8)
(8W-15-8)
(8W-15-17)
(8W-15-18)
(8W-15-17)
(8W-15-18)
(8W-12-10)
ZG-RHD 8W-42 AIR CONDITIONING-HEATER
MANUAL
8W - 42 - 7
ZGR04206 J978W-3
M
2
1
M
3 6 5
3 5 4
BLEND
DOOR
ACTUATOR
ACTUATOR
DOOR
MODE
1
2
AUTOMATIC
TEMPERATURE
CONTROL
MODULE
C14
C3 C1
D6 C2
D1 C8
AUTOMATIC
TEMPERATURE
CONTROL
MODULE
MODE
DOOR
MOTOR
DRIVER
MODE
DOOR
MOTOR
POSITION
SENSE
5V
SUPPLY
DRIVER
MOTOR
DOOR
MODE
BLEND
AIR
DOOR
MOTOR
DRIVER
SIGNAL
FEEDBACK
DOOR
AIR
BLEND
DRIVER
MOTOR
DOOR
AIR
BLEND
C35
20
DG/YL
C35
20
DB/WT
C34
20
DB/WT
C34
20
VT/WT
C E C206
C36
20
RD/WT
C36
20
DB/RD
D C206
C40
20
DG/YL
C40
20
DG/YL
D41
20
LG/WT
D41
20
LG/WT
C38
20
DG
C38
20
DB
C37
20
TN/BK
C37
20
YL
C39
20
YL
C39
20
WT
S222
C40
20
DG/YL
C40
20
BR/WT
C206
S223
J B C206
A C206
S219
C206 S
LG/WT
20
D41
LG/WT
20
D41
LG/WT
20
D41
D9
K
SENSOR
GROUND
(8W-42-6)
8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER
ATC
ZG-RHD
J978W-3 ZGR04207
12
FUSE
10A
F71
20
PK/DG
F71
20
DG/PK
RECIRCULATION
DOOR
MOTOR
DRIVER DRIVER
MOTOR
DOOR
RECIRCULATION
FUSED
IGN.
(RUN)
C32
20
DB/GY
C33
20
DB/RD
F71
20
PK/DG
F71
20
PK/DG
F G C206
5 4 1
D3 D4
H
S218
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
ACTUATOR
DOOR
RECIRCULATION
C32
20
LB/DG
C33
20
VT/OR
C12
9 C9 4 C9
JUNCTION
BLOCK
RUN A22
RECIRC.
DOOR
MOTOR MOTOR
DOOR
RECIRC.
IGN.
FUSED
(RUN)
18 18
VT/BR WT/BK
CCD
(+)
BUS
18
VT/BR
D1
D1
3
LINK
DATA
S203
CONNECTOR
S204
D2
WT/BK
18
D2
BUS
CCD
11
(-)
C10 C11
(+)
CCD
BUS BUS
CCD
(-)
PAIR
TWISTED
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-19)
(8W-30-31)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-10-8)
(8W-12-2)
(8W-12-10)
(8W-12-10)
ZG-RHD 8W-42 AIR CONDITIONING-HEATER
ATC
8W - 42 - 9
ZGR04208 J978W-3
18
FUSE
15A
A15
ST-RUN A21
A16
F99
18
OR
F99
20
OR
S101
CENTER
DISTRIBUTION
POWER
B3 B1
B2 B5
C2
18
DB/YL
C2
18
DB/YL
C2
18
DB/YL
C2
18
DB/YL
C2
18
DB/YL
1 C144 7 C131
C2
18
DB/YL
C13
18
DB/RD
E
(8W-42-12)
TO
MODULE
CONTROL
POWERTRAIN
4.0L 5.2L
BATT A900
21
FUSE
15A
A21
A22
F250
18
RD/GY
CLUTCH
COMPRESSOR
A/C
A/C
COMPRESSOR
CLUTCH
RELAY
(IN PDC)
(8W-10-4)
(8W-10-4)
(8W-10-8)
(8W-10-3)
(8W-10-15)
(8W-10-13)
8W - 42 - 10 8W-42 AIR CONDITIONING-HEATER
GAS ENGINES
ZG-RHD
J978W-3 ZGR04209
21
FUSE
15A
A21
A22
F250
18
RD/GY
CENTER
DISTRIBUTION
POWER
B1 B3
B2 B5
C2
18
DB/YL
C2
18
DB/YL
1 C144
C3
18
DB/BK
I
(8W-42-13)
BATT A0
20
FUSE
25A
A20
A19
CLUTCH
COMPRESSOR
A/C
A/C
COMPRESSOR
CLUTCH
RELAY
(IN PDC)
(IN PDC)
RELAY
DOWN
SHUT
AUTOMATIC
B17
B18 B16
TO
C131
A142
16
DG/OR
F5 16 RD/YL
F5
16
RD/YL
9
2
40A
FUSE
3
A900
16
OR/YL
(8W-10-4)
(8W-10-3)
(8W-10-16)
(8W-10-3)
(8W-10-4)
ZG-RHD 8W-42 AIR CONDITIONING-HEATER
DIESEL ENGINE
8W - 42 - 11
ZGR04211 J978W-3
E
(8W-42-10)
FROM
CLUTCH
COMPRESSOR
A/C
C3 C1
A/C
COMPRESSOR
CLUTCH
RELAY
CONTROL
MODULE
CONTROL
POWERTRAIN
C13
18
DB/RD
A/C
PRESSURE
SWITCH
C22
C3
C3
18
DB/BK
1
2
SWITCH
PRESSURE
LOW
A/C
C21
18
DB/OR
C21
18
DB/OR
A/C
HIGH
PRESSURE
SWITCH
2
1
5 C144
G106
Z1
18
BK
Z1
18
BK
4 C144
Z1
14
BK
S104
RELAY
(8W-15-7)
(8W-15-7)
(8W-30-6)
8W - 42 - 12 8W-42 AIR CONDITIONING-HEATER
GAS ENGINES
ZG-RHD
J978W-3 ZGR04210
C13
18
DB/BK
C3
18
DB/BK
2
1
SWITCH
PRESSURE
HIGH
A/C
C21
18
DB/OR
C21
18
DB/OR
A/C
LOW
PRESSURE
SWITCH
1
2
5 C144
14 C131
28
CONTROLLER
MSA
A/C
COMPRESSOR
CLUTCH
RELAY
CONTROL
C13
16
DB/RD
C13
16
DB/RD
10 C132
A/C
COMPRESSOR
CLUTCH
RELAY
FROM
I
(8W-42-11)
DG
20
C103
37
A/C
SWITCH
SIGNAL
59
C4
POWERTRAIN
CONTROL
MODULE
A/C
SWITCH
SIGNAL
(8W-30-29)
(8W-30-22)
ZG-RHD 8W-42 AIR CONDITIONING-HEATER
DIESEL ENGINE
8W - 42 - 13
ZGR04212 J978W-3
8W-42 AIR CONDITIONING/HEATER
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION AND OPERATION
A/C OPERATIONAUTOMATIC TEMPERATURE
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A/C OPERATIONMANUAL A/C . . . . . . . . . . . . 14
AMBIENT TEMPERATURE SENSOR . . . . . . . . . 15
AUTOMATIC TEMPERATURE CONTROL (ATC)
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AUTOMATIC TEMPERATURE CONTROL (ATC) . 15
BLEND AIR DOOR MOTOR ACTUATOR
MANUAL A/C-HEATER . . . . . . . . . . . . . . . . . . 15
BLEND DOOR MOTORAUTOMATIC
TEMPERATURE CONTROL . . . . . . . . . . . . . . 16
BLOWER MOTORAUTOMATIC
TEMPERATURE CONTROL . . . . . . . . . . . . . . 16
BLOWER MOTORMANUAL A/C-HEATER . . . . 14
IN-CAR TEMPERATURE SENSOR . . . . . . . . . . 15
MANUAL A/C-HEATER . . . . . . . . . . . . . . . . . . . 14
MODE DOOR MOTORAUTOMATIC
TEMPERATURE CONTROL . . . . . . . . . . . . . . 16
RECIRCULATION DOOR MOTORAUTOMATIC
TEMPERATURE CONTROL . . . . . . . . . . . . . . 16
SOLAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL INFORMATION
INTRODUCTION
Thi s secti on of the wi ri ng di agrams i s di vi ded i nto
two sub-secti ons; Manual A/C-Heater, and Automati c
Temperature Control (ATC). When referri ng to the
ci rcui t descri pti ons or wi ri ng di agrams, ensure that
you use the correct one.
DESCRIPTION AND OPERATION
MANUAL A/C-HEATER
Several fuses suppl y power for the manual ai r con-
di ti oni ng/heater system. When the i gni ti on swi tch i s
i n the RUN posi ti on, i t connects ci rcui t A1 from fuse
8 i n the Power Di stri buti on Center (PDC) to ci rcui t
A22. Ci rcui t A22 powers ci rcui t F71 through fuse 12
i n the juncti on bl ock. Ci rcui t F71 connects to the A/C
control swi tches and the bl end ai r door motor.
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 to ci rcui t A21. Ci rcui t
A21 powers ci rcui t F99 through fuse 18 i n the PDC.
Ci rcui t F99 powers the coi l si de of the A/C compres-
sor cl utch rel ay.
Ci rcui t A900 from fuse 3 i n the PDC powers ci rcui t
F250 through fuse 21 i n the PDC. Ci rcui t F250 pow-
ers the contact si de of the A/C compressor cl utch
rel ay.
Ci rcui t E2 from the headl amp di mmer swi tch pow-
ers the case grounded i l l umi nati on l amp i n the A/C-
heater control swi tch.
BLOWER MOTOR MANUAL A/C-HEATER
The bl ower motor swi tch has four posi ti ons; LOW,
MEDI UM 1, MEDI UM 2, AND HI GH. Ci rcui t A19
from fuse 7 i n the PDC suppl i es power to the bl ower
motor. Ground for the bl ower motor i s suppl i ed on
ci rcui t C7 through the bl ower motor resi stor bl ock to
the bl ower motor swi tch, through an i nternal rel ay i n
the A/C-Heater Control head. When the i nternal
rel ay energi zes, i t connects the bl ower motor swi tch
to ci rcui t C1. Ci rcui t C1 connects to ground ci rcui t
Z4.
I n the HI GH posi ti on, the bl ower motor swi tch con-
nects ci rcui t C7 from the bl ower motor di rectl y to
ground on ci rcui ts C1 and Z4. I n the LOW or
MEDI UM posi ti ons, the ground path passes through
the bl ower motor resi stor bl ock to the swi tch. The
swi tch connects the ci rcui t C1.
The bl ower motor resi stor bl ock consi sts of three
resi stors connected i n seri es. Dependi ng on bl ower
motor swi tch posi ti on, the ground path on ci rcui t C7
from the bl ower motor passes through one or more
resi stors to ci rcui t C1.
When the bl ower motor swi tch i s i n the LOW posi -
ti on, the ground path passes through al l three resi s-
tors i n the bl ower motor resi stor bl ock to ci rcui t C4.
The bl ower motor swi tch connects ci rcui t C4 to ci r-
cui ts C1 and Z4.
I n the MEDI UM 1 posi ti on, the ground path
passes through two resi stors i n the resi stor bl ock to
ci rcui t C5. The bl ower motor swi tch connects ci rcui t
C5 to ci rcui ts C1 and Z4.
I n the MEDI UM 2 posi ti on, the ground path
passes through one resi stor i n the resi stor bl ock to
ci rcui t C6. The bl ower motor swi tch connects ci rcui t
C6 to ci rcui ts C1 and Z4.
A/C OPERATION MANUAL A/C
When the A/C-heater control swi tch i s moved to an
A/C posi ti on or the defrost posi ti on, the Body Control
8W - 42 - 14 8W - 42 AIR CONDITIONING/HEATER ZG
Modul e (BCM) recei ves the A/C sel ect si gnal on ci r-
cui t C90. After recei vi ng the i nput, the BCM si gnal s
the Powertrai n Control Modul e (PCM) on the CCD
bus.
The A/C l ow pressure and hi gh pressure swi tches
are wi red i n seri es and connect to ground on ci rcui t
Z1. Ci rcui t C3 from the PCM connects to the l ow
pressure swi tch. Ci rcui t C21 connects the l ow pres-
sure swi tch to the hi gh pressure swi tch. The hi gh
pressure swi tch connects ci rcui t C21 to ground ci r-
cui t Z1. I f the A/C l ow pressure and hi gh pressure
swi tches are cl osed, the PCM senses the A/C request
si gnal on ci rcui t C3.
After sensi ng the A/C request si gnal , the PCM sup-
pl i es ground for the coi l si de of A/C compressor cl utch
rel ay on ci rcui t C13. Ci rcui t F99 from fuse 18 i n the
PDC powers the coi l si de of the rel ay.
When the PCM grounds the A/C compressor cl utch
rel ay, the contacts cl ose and connect ci rcui t F250
from fuse 21 i n the PDC to ci rcui t C2. Ci rcui t C2
suppl i es power to the case grounded A/C compressor
cl utch.
The A/C compressor cl utch has a bui l t-i n di ode.
The di ode control s the i nduced vol tage that resul ts
from the magneti c fi el d col l apsi ng when the cl utch
di sengages. The di ode provi des a current path to pro-
tect other components and systems.
HELPFUL INFORMATION
Ci rcui t A900 from fuse 3 i n the PDC powers ci rcui t
F250 through PDC fuse 21.
BLEND AIR DOOR MOTOR ACTUATOR MANUAL
A/C-HEATER
The A/C-Heater control head contai ns a bl end door
posi ti on sensor. The sensor i s a vari abl e resi stor that
provi des the bl end door posi ti on i nput to the bl end
door motor actuator on ci rcui t C36.
Ci rcui t F71 from fuse 12 i n the juncti on bl ock pow-
ers the actuator when the i gni ti on swi tch i s i n the
RUN posi ti on. Ci rcui t C34 spl i ces to connect the
bl end door actuator to ground ci rcui t Z1.
AUTOMATIC TEMPERATURE CONTROL (ATC)
Several fuses suppl y power for the Automati c Tem-
perature Control (ATC) system. When the i gni ti on
swi tch i s i n the RUN posi ti on, i t connects ci rcui t A1
from fuse 8 i n the Power Di stri buti on Center (PDC)
to ci rcui t A22. Ci rcui t A22 powers ci rcui t F71
through fuse 12 i n the juncti on bl ock. Ci rcui t F71
connects to the ATC modul e and the reci rcul ati on
door motor.
Ci rcui t A7 from fuse 15 i n the PDC powers ci rcui t
F60 through fuse 20 i n the juncti on bl ock. Ci rcui t
F60 suppl i es power to the ATC modul e.
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from PDC fuse 8 to
ci rcui t A21. Ci rcui t A21 powers ci rcui t F99 through
fuse 18 i n the PDC. Ci rcui t F99 powers the coi l si de
of the A/C compressor cl utch rel ay.
Ci rcui t A19 from fuse 7 i n the PDC connects to the
bl ower power modul e and to the coi l and contact
si des of the hi gh speed bl ower motor rel ay.
AUTOMATIC TEMPERATURE CONTROL (ATC)
MODULE
Ci rcui t F71 suppl i es battery vol tage to the Auto-
mati c Temperature Control (ATC) modul e when the
i gni ti on swi tch i s i n the RUN posi ti on. Ci rcui t F60
from fuse 20 i n the juncti on bl ock connects to the
ATC modul e. Ci rcui t F60 i s HOT at al l ti mes. Ci rcui t
Z4 provi des ground for the ATC modul e.
Ci rcui t E2 from the headl amp di mmer swi tch con-
nects to the ATC modul e.
The ATC modul e communi cates wi th other vehi cl e
modul es and control l ers on the CCD bus. Ci rcui ts D1
and D2 for the CCD Bus connect to the ATC modul e.
AMBIENT TEMPERATURE SENSOR
The ambi ent temperature sensor i s a vari abl e
resi stor. Ci rcui t C8 provi des the ambi ent tempera-
ture sensor si gnal to the ATC modul e. Ci rcui t D41
provi des ground for the sensor. Ci rcui t D41 connects
to the ATC modul e.
IN-CAR TEMPERATURE SENSOR
The i n-car temperature sensor i s a vari abl e resi s-
tor. Ci rcui t C10 provi des the i n-car temperature sen-
sor si gnal to the ATC modul e. Ci rcui t D41 provi des
ground for the sensor. Ci rcui t D41 connects to the
ATC modul e.
SOLAR SENSOR
The sol ar sensor i s a vari abl e resi stor. Ci rcui t C47
from the ATC modul e connects to the sol ar sensor.
Ci rcui t D41 provi des ground for the sensor. Ci rcui t
D41 connects to the ATC modul e.
A/C OPERATION AUTOMATIC TEMPERATURE
CONTROL
When the A/C sel ect swi tch i n the Automati c Tem-
perature Control (ATC) control head cl oses ci rcui t
C90 provi des the A/C sel ect si gnal to the Body Con-
trol Modul e (BCM). After recei vi ng the i nput, the
BCM si gnal s the Powertrai n Control Modul e (PCM)
on the CCD bus.
The A/C l ow pressure and hi gh pressure swi tches
are wi red i n seri es and connect to ground on ci rcui t
Z1. Ci rcui t C3 from the PCM connects to the l ow
pressure swi tch. Ci rcui t C21 connects the l ow pres-
sure swi tch to the hi gh pressure swi tch. The hi gh
ZG 8W - 42 AIR CONDITIONING/HEATER 8W - 42 - 15
DESCRIPTION AND OPERATION (Continued)
pressure swi tch connects ci rcui t C21 to ground ci r-
cui t Z1. I f the A/C l ow pressure and hi gh pressure
swi tches are cl osed, the PCM senses the A/C request
si gnal on ci rcui t C3.
After sensi ng the A/C request si gnal , the PCM sup-
pl i es ground for the coi l si de of A/C compressor cl utch
rel ay on ci rcui t C13. Ci rcui t F99 from fuse 18 i n the
PDC powers the coi l si de of the rel ay.
When the PCM grounds the A/C compressor cl utch
rel ay, the contacts cl ose and connects ci rcui t F250
from fuse 21 i n the PDC to ci rcui t C2. Ci rcui t C2
suppl i es power to the case grounded A/C compressor
cl utch.
The A/C compressor cl utch has a bui l t-i n di ode.
The di ode control s the i nduced vol tage that resul ts
from the magneti c fi el d col l apsi ng when the cl utch
di sengages. The di ode provi des a current path to pro-
tect other components and systems.
HELPFUL INFORMATION
Ci rcui t A900 from fuse 3 i n the PDC powers ci rcui t
F250 through PDC fuse 21.
RECIRCULATION DOOR MOTOR AUTOMATIC
TEMPERATURE CONTROL
When the i gni ti on swi tch i s i n the RUN posi ti on, i t
connects ci rcui t A1 from fuse 8 i n the Power Di stri -
buti on Center (PDC) to ci rcui t A22. Ci rcui t A22 pow-
ers ci rcui t F71 through fuse 12 i n the juncti on bl ock.
Ci rcui t F71 feeds the reci rcul ati on door motor. Ci r-
cui t F71 al so connects to the Automati c Temperature
Control (ATC) modul e.
Ci rcui ts C32 and C33 from the ATC modul e con-
nect to the reci rcul ati on door motor. Ci rcui ts C32 and
C33 provi de ground for the motor.
MODE DOOR MOTOR AUTOMATIC
TEMPERATURE CONTROL
Ci rcui t C40 from the Automati c Temperature Con-
trol (ATC) modul e suppl i es 5 vol ts to the posi ti on
swi tch i n the mode door motor. The ATC modul e
recei ves the sensor si gnal from the mode door motor
on ci rcui t C39. Ci rcui t D41 provi des ground for the
mode door posi ti on sensor. Ci rcui t D41 connects to
the ATC modul e.
The ATC modul e operates the mode door motor on
ci rcui ts C37 and C38.
BLEND DOOR MOTOR AUTOMATIC
TEMPERATURE CONTROL
Ci rcui t C40 from the Automati c Temperature Con-
trol (ATC) modul e suppl i es 5 vol ts to the posi ti on
swi tch i n the bl end door motor. The ATC modul e
recei ves the sensor si gnal from the bl end door motor
on ci rcui t C36. Ci rcui t D41 provi des ground for the
mode door posi ti on sensor. Ci rcui t D41 connects to
the ATC modul e.
The ATC modul e operates the mode door motor on
ci rcui ts C35 and C34.
BLOWER MOTOR AUTOMATIC TEMPERATURE
CONTROL
When the operator sel ects bl ower motor HI GH
speed operati on, the Automati c Temperature Control
(ATC) modul e grounds hi gh speed bl ower motor rel ay.
For any speed other than HI GH, the bl ower power
modul e suppl i es battery vol tage for the bl ower motor.
BLOWER MOTOR POWER MODULE
When the operator sel ects any bl ower motor speed
other than HI GH, the bl ower motor power modul e
suppl i es vol tage for the bl ower motor. Ci rcui t A19
from fuse 7 i n the Power Di stri buti on Center (PDC)
suppl i es battery vol tage to the bl ower motor power
modul e.
The vol tage l evel fed to the bl ower motor depends
on the bl ower speed sel ected by the operator. Sl ower
speed sel ecti ons provi de l ower vol tage to the motor.
The bl ower motor power modul e feeds the bl ower
motor on ci rcui t C42. Ci rcui t Z4 provi des ground for
the bl ower motor and the bl ower motor power mod-
ul e.
Ci rcui t C43 from the power modul e connects to the
ATC modul e. The ATC modul e control s feedback on
ci rcui t C43.
HIGH SPEED BLOWER MOTOR RELAY
Ci rcui t A19 from fuse 7 i n the Power Di stri buti on
Center suppl i es battery vol tage to the coi l and con-
tacts si des of the hi gh speed bl ower motor rel ay. The
ATC modul e provi des ground for the coi l si de of the
rel ay on ci rcui t C41.
When the ATC modul e grounds the hi gh speed
bl ower motor rel ay, the rel ay contacts cl ose and con-
nect ci rcui t A19 to ci rcui t C42. Ci rcui t C42 connects
to the bl ower motor and the ATC modul e. Ci rcui t Z4
provi des ground for the bl ower motor.
8W - 42 - 16 8W - 42 AIR CONDITIONING/HEATER ZG
DESCRIPTION AND OPERATION (Continued)
8W-43 AIRBAG SYSTEM
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-43-2, 3
Ai rbag Warni ng Lamp . . . . . . . . . . . . . . . . . 8W-43-3
Dri ver Si de Ai rbag . . . . . . . . . . . . . . . . . . . 8W-43-2
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-43-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
Passenger Si de Ai rbag . . . . . . . . . . . . . . . . . 8W-43-2
Component Page
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
ZG 8W - 43 AIRBAG SYSTEM 8W - 43 - 1
10A
FUSE
4
BLOCK
JUNCTION
ST-RUN A21
22
FUSE
10A
RUN A22
1
C13 C14
2
F20
18
WT DB/WT
18
G5
20 17
AIRBAG
CONTROL
MODULE
FUSED
IGN.
(RUN) (ST-RUN)
IGN.
FUSED
2
R43
18
BK/LB
2 1
DG/LB
18
R45
1
DRIVER
AIRBAG
LINE 1 LINE 2
AIRBAG
DRIVER
DRIVER
AIRBAG
LINE 1 LINE 2
AIRBAG
DRIVER
SIDE
AIRBAG AIRBAG
SIDE
PASSENGER
AIRBAG
LINE 2 LINE 1
AIRBAG
PASSENGER
PASSENGER
AIRBAG
LINE 2 LINE 1
AIRBAG
PASSENGER
A
R44
18
DG/YL
6 5
BK/YL
18
R42
B
A C300 B
R42
18
VT
R44
18
DB
10
GROUND
G303
Z6
16
BK/PK
PAIR
TWISTED
PAIR
TWISTED
DRIVER PASSENGER
(8W-15-13)
(8W-12-23)
(8W-10-8) (8W-10-8)
(8W-12-2)
(8W-12-5)
8W - 43 - 2 8W-43 AIRBAG SYSTEM ZG-RHD
J978W-3 ZGR04301
BATT A250
1 2
Z1
20
BK
S216
Z1
16
BK
S202
Z1
14
BK
2 C301
Z1
14
BK
BK/OR
18
Z2
S205
BK/OR
20
Z2
8 C307
Z2
18
BK/OR
S302
Z2
18
BK/OR
G304
7
FUSE
20A
BLOCK
JUNCTION
C4
8
AIRBAG
WARNING
LAMP
GROUND
CLUSTER
INSTRUMENT
F75
18
VT
F75
18
VT
S201
CCD
BUS (+) BUS (-)
CCD
8 9
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
1
C302
2
WT/BK
18
D2
WT/BK
18
D2
WT/BK
18
D2
S204 S203
S306 S307
19 18
CCD
BUS (+)
CCD
BUS (-)
AIRBAG
CONTROL
MODULE
3
PAIR
TWISTED
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-12-8)
(8W-40-2)
(8W-40-3)
(8W-12-2)
(8W-12-8)
(8W-15-18)
(8W-15-18)
(8W-15-18)
(8W-15-18)
(8W-15-17)
(8W-10-10)
ZG-RHD 8W-43 AIRBAG SYSTEM 8W - 43 - 3
ZGR04302 J978W-3
8W-43 AIRBAG SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
AIRBAG IMPACT SENSOR . . . . . . . . . . . . . . . . . 4
AIRBAG SQUIB (AIRBAG IGNITER) . . . . . . . . . . 4
AIRBAG WARNING LAMP . . . . . . . . . . . . . . . . . . 4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
INTRODUCTION
Thi s vehi cl e has a dri vers ai rbag and a passengers
ai rbag. The Ai rbag Control Modul e (ACM) operates
both. The ai rbag system has two sensors, l ocated at
the l eft front and ri ght front of the engi ne compart-
ment.
I n the START or RUN posi ti on, the i gni ti on swi tch
connects ci rcui t A1 from fuse 8 i n the Power Di stri -
buti on Center (PDC) to ci rcui t A22. Ci rcui t A22 pow-
ers ci rcui t F20 through fuse 22 i n the juncti on bl ock.
Ci rcui t F20 connects to the ACM.
When the i gni ti on swi tch i s i n the RUN posi ti on, i t
connects ci rcui t A1 to ci rcui t A21. Ci rcui t A21 powers
ci rcui t G5 through fuse 4 i n the juncti on bl ock. Ci r-
cui t G5 connects to the ACM. Ci rcui t Z6 provi des
ground for the ACM.
Ci rcui t A250 from fuse 11 i n the PDC powers ci r-
cui t F75 through fuse 7 i n the juncti on bl ock. Ci rcui t
F75 powers the ai rbag warni ng l amp i n the i nstru-
ment cl uster.
AIRBAG IMPACT SENSOR
The Ai rbag system uses a sensor i nternal to the
Ai rbag Control Modul e (ACM) to detect i mpact. For
i nformati on regardi ng operati on of thi s sensor, refer
to the appropri ate group of the Servi ce Manual .
AIRBAG SQUIB (AIRBAG IGNITER)
Ci rcui ts, R43 and R45, connect the ACM to the
dri vers ai rbag squi b (i gni ter) after passi ng through
the cl ock spri ng connector. Ci rcui t R43 from cavi ty 2
of the ACM 4-way connector connects to the squi b.
Ci rcui t R45 from cavi ty 1 of the ACM 4-way connec-
tor connects to the squi b.
Ci rcui ts, R42 and R44, connect the ACM to the
passenger ai rbag squi b (i gni ter). Ci rcui t R42 from
cavi ty 5 of the ACM 4-way connector connects to the
squi b. Ci rcui t R44 from cavi ty 6 of the ACM 4-way
connector connects to the squi b.
AIRBAG WARNING LAMP
Ci rcui t F75 from fuse 7 i n the juncti on bl ock feeds
the ai rbag warni ng l amp. Ground ci rcui t Z1 connects
to the warni ng l amp through a transi stor control l ed
by the mi croprocessor i n the i nstrument cl uster.
When the mi croprocessor recei ves a si gnal from Ai r-
bag Control Modul e (ACM) on the CCD bus, i t
swi tches the transi stor to connect the l amp to
ground.
8W - 43 - 4 8W - 43 AIRBAG SYSTEM ZG
8W-44 INTERIOR LIGHTING
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Component Page
A/C Heater Control . . . . . . . . . . . . . . . . . . 8W-44-12
Ash Recei ver Lamp . . . . . . . . . . . . . . . 8W-44-11, 12
Automati c Day/Ni ght Mi rror . . . . . . . . . . 8W-44-6, 7
Automati c Temperature Control Modul e . . 8W-44-12
Body Control
Modul e . . . . . . 8W-44-2, 5, 8, 9, 10, 11, 12, 13, 14
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5
Ci gar Li ghter Lamp . . . . . . . . . . . . . . . . . 8W-44-12
Ci rcui t Breaker 2 . . . . . . . . . . . . . . . . . 8W-44-9, 10
Courtesy Lamp Rel ay . . . . . . . . . 8W-44-2, 3, 4, 5, 8
Dome/Readi ng Lamp . . . . . . . . . . . . . . . . . . 8W-44-3
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . 8W-44-9
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . 8W-44-7
Fl oor Consol e Lamps . . . . . . . . . . . . . . . . . 8W-44-11
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
Fuse 16 . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4, 5, 8
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-13
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-14
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-10
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-9
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8
G304 . . . . . . . . . . . . . . . . . . 8W-44-2, 7, 8, 11, 12, 13
G305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . . 8W-44-2
Graphi c Di spl ay Modul e . . . . . . . . . . . . . . 8W-44-12
Headl amp Swi tch . . . . . . . . . . . . . . . . . 8W-44-11, 13
I l l umi nati on . . . . . . . . . . . . . . . . . . . . . . . 8W-44-13
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-44-11
Juncti on Bl ock . . . 8W-44-2, 3, 4, 5, 6, 7, 8, 9, 10, 13
Key-I n Swi tch/Hal o Lamp . . . . . . . . . . . . . . 8W-44-2
Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-13
Left Courtesy Lamp . . . . . . . . . . . . . . . . 8W-44-2, 8
Left Door Courtesy Lamp . . . . . . . . . . . . . . 8W-44-9
Left Front Door Ajar Swi tch . . . . . . . . . . . 8W-44-14
Left Rear Door Ajar Swi tch . . . . . . . . . . . . 8W-44-14
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . 8W-44-5
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-44-14
Li ftgl ass Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-44-14
Mercury Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
Overhead Consol e . . . . . . . . . . . . . . . . . . . . 8W-44-4
Component Page
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . 8W-44-6
Passenger Door Modul e . . . . . . . . . . . . . . . 8W-44-10
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8
Rear Wi per Modul e . . . . . . . . . . . . . . . . . . 8W-44-14
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . 8W-44-2, 8
Ri ght Door Courtesy Lamp . . . . . . . . . . . . 8W-44-10
Ri ght Front Door Ajar Swi tch . . . . . . . . . . 8W-44-14
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . 8W-44-14
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . 8W-44-5
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
S202 . . . . . . . . . . . . . . . . . . 8W-44-2, 7, 8, 11, 12, 13
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-9, 10
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-9, 10
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11
S209 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11, 12, 13
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11, 12
S216 . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 7, 8, 11, 12
S220 . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 7, 8, 12
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-9, 10
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-9, 10
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-14
S321 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3, 4, 5
S322 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3, 4, 5, 7
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-9
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-10
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-14
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-14
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3, 4
Swi tch Pod . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-44-2
Uni versal Garage Door Opener . . . . . . . . . . 8W-44-5
Vehi cl e I nformati on Center . . . . . . . . . . . . 8W-44-12
ZG 8W - 44 INTERIOR LIGHTING 8W - 44 - 1
16
FUSE
10A
BATT A7
C8 8 6 C8 C3 1 C8 3 11 C8
1
2
B
A
LAMP
COURTESY
LEFT RIGHT
COURTESY
LAMP
A
B
LAMP
BOX
GLOVE
3
4
M1
20
PK
M1
20
PK
M1
20
PK
M1
20
PK
LAMP
HALO
KEY-IN
87
30
C5
4
C8 12 7 C8 C8 2
COURTESY
LAMP
RELAY
JUNCTION
BLOCK
Z1
20
BK
Z1
18
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
M2
20
YL
M2
20
YL
M2
20
YL
Z1
14
BK
S220
S202
2 C301
G304
MERCURY
SWITCH
UNDERHOOD
LAMP
1
2
G107
Z4
18
BK
Z4
10
BK
S124
M1
18
PK
M1
18
PK
1 C159
JUNCTION
BLOCK
SWITCH/
SWITCH/
KEY-IN
HALO
LAMP
2
1
14
MODULE
CONTROL
BODY
C1
SWITCH
IGN.
KEY-IN
SENSE
BK
20
Z1
S216
LB
20
G26
C159 2
G107
S109
BK
Z4
10
BK
Z4
18
BK
14
Z1
GAS DIESEL
(8W-15-4)
(8W-15-5)
(8W-15-8)
(8W-15-17)
(8W-45-3)
(8W-12-2)
(8W-15-8)
(8W-15-8) (8W-15-18)
(8W-15-18)
(8W-15-17)
(8W-12-2)
(8W-44-8)
(8W-10-12)
(8W-12-12)
8W - 44 - 2 8W-44 INTERIOR LIGHTING ZG-RHD
J978W-3 ZGR04401
16
FUSE
10A
BATT A7
9 C15
M1
20
PK
M1
20
PK
S321
A
C
B
LAMP
READING
DOME/
M2
20
YL
M2
20
YL
M2
20
YL
M2
20
YL
S334
87
30
C15 11
COURTESY
LAMP
RELAY
JUNCTION
BLOCK
2 C15
Z1
20
BK
Z1
16
BK
S322
OTHERS SUNROOF
JUNCTION
BLOCK
(8W-12-2)
(8W-15-16)
(8W-12-2)
(8W-44-8)
(8W-12-21)
(8W-12-13)
(8W-10-12)
(8W-12-12)
ZG-RHD 8W-44 INTERIOR LIGHTING 8W - 44 - 3
ZGR04402 J978W-3
16
FUSE
10A
BATT A7
9 C15
M1
20
PK
M1
20
PK
S321
2
6
4
M2
20
YL
M2
20
YL
M2
20
YL
M2
20
YL
S334
87
30
C15 11
COURTESY
LAMP
RELAY
JUNCTION
BLOCK
2 C15
Z1
20
BK
Z1
16
BK
S322
OTHERS SUNROOF
OVERHEAD
CONSOLE
JUNCTION
BLOCK
(8W-49-2)
(8W-49-3)
(8W-12-2)
(8W-15-16)
(8W-12-2)
(8W-44-8)
(8W-12-21)
(8W-12-13)
(8W-10-12)
(8W-12-12)
8W - 44 - 4 8W-44 INTERIOR LIGHTING ZG-RHD
J978W-3 ZGR04403
16
FUSE
10A
BATT A7
9 C15
M1
20
PK
M1
20
PK
B
A
87
30
COURTESY
LAMP
RELAY
JUNCTION
BLOCK
2 C15
Z1
20
BK
Z1
16
BK
S322
BK
20
Z1
A
B
S321
PK
20
M1
LAMP
VANITY
VISOR/
LEFT RIGHT
VISOR/
VANITY
LAMP
LAMP
CARGO
C
B
A
C13 5
M1
20
PK
3 C14
C3 6
LIFTGATE
COURTESY
LAMP
DISABLE
M2
20
YL
M4
20
WT/LG
OPENER
DOOR
GARAGE
UNIVERSAL
JUNCTION
BLOCK
MODULE
CONTROL
BODY
(8W-45-10)
(8W-12-2)
(8W-12-13)
(8W-12-21)
(8W-12-2)
(8W-44-8)
(8W-10-12)
(8W-12-12)
ZG-RHD 8W-44 INTERIOR LIGHTING 8W - 44 - 5
ZGR04404 J978W-3
6
FUSE
15A
RUN A22
1 C8
JUNCTION
BLOCK
F83
18
YL/DG
F83
18
YL/DG
F83
18
YL/DG
S212
18
C235
12
SPEED
PROPORTIONAL
STEERING OTHERS
F83
18
YL/DG
F83
18
YL/DG
F83
18
YL/DG
S119
8 C132
C15 3
OVERHEAD
CONSOLE OTHERS
F83
20
BK/VT
F83
20
YL/DG
F83
20
BK/VT
S323
1
MIRROR
NIGHT
DAY/
AUTOMATIC
FUSED
IGN.
(RUN)
OUTPUT
SWITCH
LAMP
BACK-UP
3
DAY/
NIGHT
MIRROR
(-) (+)
DRIVER
POWER
MIRROR
P114
20
YL/BK
P114
18
YL/BK
P114
20
YL/BK
P112
20
YL/WT
P112
18
YL/WT
P112
20
YL/WT
11 C334
7 C302
3 C231
B C353 A
9
8
4
AUTOMATIC
NIGHT
DAY/
AUTOMATIC
MIRROR
S322
BK
16
Z1
BK
20
Z1
2
C
(8W-44-7)
JUNCTION
BLOCK
TO
L10
20
BK/RD
B
(8W-44-7)
JUNCTION
BLOCK
TO
BK/RD
20
L10
A
(8W-44-7)
PARK/
NEUTRAL
POSITION
SWITCH
TO
GROUND
AUTOMATIC
DAY/
NIGHT
MIRROR
(-) (+)
MIRROR
NIGHT
DAY/
AUTOMATIC
5 4
(8W-12-7)
(8W-12-6)
(8W-12-6)
(8W-12-2)
(8W-10-7)
(8W-12-6)
(8W-62-4)
(8W-12-21)
8W - 44 - 6 8W-44 INTERIOR LIGHTING ZG-RHD
J978W-3 ZGR04405
G304
C301 2
S202
S216
S220
BK
14
Z1
BK
16
Z1
BK
16
Z1
BK
18
Z1
BLOCK
JUNCTION
2 C15
4
C5
BK
16
Z1
18
L10
BR/LG
C131 6
BK/RD
20
L10
7 C15
2
C3
BR/LG
18
L10
PARK/
NEUTRAL
POSITION
SWITCH
3
1
YL/DG
18
F83
C
(8W-44-6)
FROM
S322
B
(8W-44-6)
AUTOMATIC
DAY/
NIGHT
MIRROR
FROM
T41
20
BK/WT
2
S134
T41
18
BK/WT
C1
A6
POWERTRAIN
CONTROL
MODULE
PARK/
NEUTRAL
POSITION
SWITCH
SENSE
A
(8W-44-6)
FROM
C132
(8W-12-2)
(8W-15-17)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-15-6)
(8W-21-4)
(8W-30-10)
ZG-RHD 8W-44 INTERIOR LIGHTING 8W - 44 - 7
ZGR04406 J978W-3
C5
4
86
85 87
BATT A7
10A
FUSE
16
JUNCTION
BLOCK
6
C10
M112
20
BR/LG
MODULE
CONTROL
BODY
C2 6
COURTESY
LAMP
RELAY
CONTROL
G304
Z1
14
BK
Z1
14
BK
Z1
16
BK
Z1
16
BK
Z1
18
BK
S202
S216
S220
2 C301
E2
20
OR
5
RADIO
C1
Z5
16
BK
Z5
14
BK/LB
9
C305
Z5
14
BK/LB
Z5
14
BK/LB
Z5
14
BK/LB
S309
G303
OTHERS AMPLIFIER
POWER
D
(8W-44-12)
FROM
S214
30
C8
12 7
C8
B
COURTESY
LAMP
LEFT
M2
YL
20
COURTESY
LAMP
RIGHT
20
YL
M2
B
12
COURTESY
LAMP
RELAY
(8W-44-2)
(8W-44-2)
(8W-15-13)
(8W-15-13)
(8W-47-2)
(8W-15-17)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-45-3)
(8W-12-2)
(8W-12-12)
(8W-10-12)
8W - 44 - 8 8W-44 INTERIOR LIGHTING ZG-RHD
J978W-3 ZGR04407
C14
7
JUNCTION
BLOCK
BATT A250
30A
2
BREAKER
CIRCUIT
F81
12
TN
F81
12
TN
3 C334
C1
9
C1 12
DRIVER
DOOR
MODULE
FUSED
B (+)
MUX
COURTESY
LAMP
DRIVER GROUND (-)
BUS
CCD CCD
BUS
(+)
8
C1
11
C1 C1
7
C1 19 20 C1
MODULE
CONTROL
BODY
CCD
BUS
(+) (-)
BUS
CCD
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
12 C334
S307
2 C302
S203 S204
1
S306
13
Z1
12
BK
Z1
12
BK
Z1
12
BK
Z1
12
BK
Z1
20
BK
M1
20
PK
2
1
LAMP
COURTESY
DOOR
Z1
12
BK
FULL
OPTION
S324
1 C334
G302
POWER
GROUP
PAIR
TWISTED
LEFT
(8W-15-12)
(8W-15-12)
(8W-30-19)
(8W-30-32)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-30-18)
(8W-30-31)
(8W-45-2)
(8W-60-2)
(8W-12-7)
(8W-10-10)
(8W-12-2)
ZG-RHD 8W-44 INTERIOR LIGHTING 8W - 44 - 9
ZGR04408 J978W-3
C14
9
JUNCTION
BLOCK
BATT A250
30A
2
BREAKER
CIRCUIT
F81
12
TN
F81
12
TN
3 C351
9
12
PASSENGER
DOOR
MODULE
FUSED
B (+)
MUX
COURTESY
LAMP
DRIVER GROUND (-)
BUS
CCD CCD
BUS
(+)
8 11 7
C1 19 20 C1
MODULE
CONTROL
BODY
CCD
BUS
(+) (-)
BUS
CCD
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
12 C351
S307
2 C302
S203 S204
1
S306
13
Z1
12
BK
Z1
12
BK
Z1
12
BK
Z1
12
BK
Z1
20
BK
M1
20
PK
2
1
LAMP
COURTESY
DOOR
Z1
12
BK
FULL
OPTION OTHERS
S325
1 C351
G301
C1 C1 C1 C1
C1
PAIR
TWISTED
RIGHT
(8W-12-2)
(8W-10-10)
(8W-12-7)
(8W-60-3)
(8W-45-2)
(8W-30-18)
(8W-30-31)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-30-19)
(8W-30-32)
(8W-15-14)
(8W-15-14)
8W - 44 - 10 8W-44 INTERIOR LIGHTING ZG-RHD
J978W-3 ZGR04409
C2
16
MODULE
CONTROL
BODY
PANEL
LAMP
DRIVER
E2
20
OR
2
3
POD
SWITCH
1
10
INSTRUMENT
CLUSTER
CLUSTER ILLUMINATION
E2
20
OR
E2
20
OR
E2
20
OR
2
Z1
20
BK
Z1
20
BK
S216
Z1
16
BK
Z1
14
BK
Z1
14
BK
S202
2 C301
E2
18
OR
6 C302
3
1
LAMPS
CONSOLE
FLOOR
Z1
20
BK
Z1
12
BK
G305
S304
Z2
20
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
S205
S302
G304
8 C307
OR
20
E2
LAMPS
ILLUM.
1
SWITCH
HEADLAMP
S209
E2
20
OR
E2
20
OR
S214
1
ASH
RECEIVER
LAMP
(8W-45-2)
(8W-40-2)
(8W-40-5)
(8W-15-17)
(8W-15-18)
(8W-15-15)
(8W-15-15)
(8W-15-18)
(8W-15-18)
(8W-45-2)
(8W-15-18)
(8W-50-2)
(8W-50-5)
(8W-50-7)
(8W-44-12)
(8W-44-12)
ZG-RHD 8W-44 INTERIOR LIGHTING 8W - 44 - 11
ZGR04410 J978W-3
C2
16
MODULE
CONTROL
BODY
PANEL
LAMP
DRIVER
E2
20
OR
S214
E2
20
OR
E2
20
OR
E2
20
OR
2
1
LAMP
RECEIVER
ASH
20
10
E2
20
OR
Z1
20
BK
Z1
20
BK
Z1
16
BK
S220
S216
Z1
16
BK
Z1
14
BK
Z1
14
BK
G304
S202
2 C301
C2 4
CONTROL
HEATER
A/C
CIGAR
LIGHTER
LAMP
E2
20
OR
E2
20
OR
D13
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
E2
20
OR
S209
MANUAL
A/C
HEATER ATC
D
(8W-44-8)
TO
RADIO
GRAPHIC
DISPLAY
MODULE
CENTER
INFORMATION
VEHICLE
10
20
E2
20
OR
Z1
20
BK
OTHERS
OVERHEAD
CONSOLE
LAMP
PANEL
PREMIUM
(8W-42-5)
(8W-46-4)
(8W-46-2)
(8W-44-11)
(8W-42-4)
(8W-15-18)
(8W-15-18)
(8W-15-17)
(8W-15-17)
(8W-45-2)
8W - 44 - 12 8W-44 INTERIOR LIGHTING ZG-RHD
J978W-3 ZGR04411
3
0 1
2
3 AUTO
2 PARK
1 HEAD
0 OFF
SWITCH
HEADLAMP
PANEL
LAMP
DIMMER
SWITCH
SIGNAL
PANEL
LAMP
DRIVER
BODY
CONTROL
MODULE
2
Z1
16
BK
Z1
14
BK
Z1
14
BK
E2
20
OR
707
20
BK/WT
G304
S202
2 C301
E2
20
OR
20
C2
16
C2
1 8
S209
LAMPS
ILLUMINATION
BATT A6
15A
FUSE
17
11
C9
366
16
PK/OR
15
JUNCTION
BLOCK
ZG-RHD 8W-44 INTERIOR LIGHTING 8W - 44 - 13
ZGR04412 J978W-3
LEFT
FRONT
DOOR
AJAR
SWITCH SWITCH
AJAR
DOOR
REAR
LEFT
SWITCH
AJAR
DOOR
FRONT
RIGHT
SWITCH
AJAR
DOOR
REAR
RIGHT
C3
4 13
C3 C3
9 3
C3
BODY
CONTROL
MODULE
LEFT
FRONT
DOOR
AJAR
SWITCH
SENSE SENSE
SWITCH
AJAR
DOOR
REAR
LEFT RIGHT
FRONT
DOOR
AJAR
SWITCH
SENSE SENSE
SWITCH
AJAR
DOOR
REAR
RIGHT
LIFTGATE
AJAR
SWITCH
SENSE
C3
1
1
2
1
2
SWITCH
AJAR
LIFTGATE LIFTGLASS
AJAR
SWITCH
G75
18
TN
G77
18
TN/OR
G74
18
TN/RD
G76
18
TN/YL
G78
20
TN/BK
G78
20
TN/BK
G78
20
TN/BK
G78
20
TN/BK
Z1
20
BK
Z1
20
BK
Z1
12
BK
Z1
12
BK
Z1
12
BK
G300
S328
S329
S316
9
C321
3
C325
MODULE
REAR
WIPER
6
TN/BK
G78
20
6
2
(8W-53-4)
(8W-15-11)
(8W-15-10)
(8W-45-11)
(8W-15-11)
(8W-45-8)
8W - 44 - 14 8W-44 INTERIOR LIGHTING ZG-RHD
J978W-3 ZGR04413
8W-44 INTERIOR LIGHTING
INDEX
page page
DESCRIPTION AND OPERATION
COURTESY LAMPS, CARGO LAMP, IGNITION
SWITCH KEY-IN HALO LAMP . . . . . . . . . . . . . 15
DAY/NIGHT MIRROR . . . . . . . . . . . . . . . . . . . . . 16
GLOVE BOX LAMP . . . . . . . . . . . . . . . . . . . . . . 16
ILLUMINATION LAMPS . . . . . . . . . . . . . . . . . . . 15
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 15
OVERHEAD CONSOLE LAMPS . . . . . . . . . . . . 16
UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . . 16
UNIVERSAL GARAGE DOOR OPENER . . . . . . . 16
VISOR VANITY MIRRORS . . . . . . . . . . . . . . . . . 16
DESCRIPTION AND OPERATION
INTRODUCTION
The Body Control Modul e (BCM) control s the cour-
tesy l amps and rear cargo l amps. The readi ng dome/
readi ng l amps i n the overhead consol e act as
courtesy l amps as wel l as contai ni ng a swi tch for
i ndependent operati on.
Ci rcui t 707 from the di mmer swi tch ci rcui try i n
the head l amp swi tch provi des the i l l umi nati on l amp
i ntensi ty si gnal to the BCM. The BCM powers the
i l l umi nati on l amps on ci rcui t E2.
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from fuse 8 i n the
PDC to ci rcui t A21. Ci rcui t A21 powers ci rcui t F99
through PDC fuse 18. Ci rcui t F99 feeds the BCM.
I n the ACCESSORY or RUN posi ti on, the i gni ti on
swi tch connects ci rcui t A1 to ci rcui t A31. Ci rcui t A31
powers ci rcui t V23 through fuse 3 i n the juncti on
bl ock. Ci rcui t V23 feeds the BCM.
ILLUMINATION LAMPS
When the headl amps or parki ng l amps are ON, the
The Body Control Modul e (BCM) recei ves the park
l amp i nput on ci rcui t L90 and the i l l umi nati on l amp
i ntensi ty si gnal on ci rcui t 707. Ci rcui t 707 from the
di mmer swi tch ci rcui try i n the head l amp swi tch pro-
vi des the i l l umi nati on l amp i ntensi ty si gnal to the
BCM.
After cal cul ati ng the requested i l l umi nati on l amp
i ntesi ty, the BCM powers the fol l owi ng i l l umi nati on
l amps on ci rcui t E2:
Headl amp swi tch
Fl oor consol e
I nstrument panel
Ash recei ver
Graphi c Di spl ay or Vehi cl e I nformati on Center
(VI C)
Ci gar l i ghter
Radi o
A/C-Heater control swi tch
Ci rcui t Z1 provi des ground for the fl oor consol e
l amps, i nstrument panel l amps, ash recei ver l amp,
graphi c di spl ay or VI C. Ci rcui t Z4 grounds the auto-
mati c temperature control swi tch l amp. Ci rcui t Z5
grounds the radi o l amp. The ci gar l i ghter l amp and
A/C-Heater control swi tch l amp (manual A/C-Heater)
are case grounded.
COURTESY LAMPS, CARGO LAMP, IGNITION
SWITCH KEY-IN HALO LAMP
When the courtesy l amp swi tch cl oses, i t connects
ci rcui t M11 from the Body Control Modul e to ground
on ci rcui t Z1. I n response to the courtesy l amp si g-
nal , the BCM energi zes the courtesy l amp rel ay by
groundi ng the rel ay coi l on ci rcui t M112. When the
rel ay energi zes, i t connects ci rcui t M2 to ground on
ci rcui t Z1. Ci rcui t M2 provi des ground for the ri ght
and l eft courtesy l amps, dome/readi ng l amps, key-i n
hal o l amp and cargo l amp.
Ci rcui t A7 from fuse 15 i n the Power Di stri buti on
Center (PDC) powers ci rcui t M1 through fuse 16 i n
the juncti on bl ock. Ci rcui t M1 powers the ri ght and
l eft courtesy l amps, i gni ti on swi tch key-i n hal o l amp,
and cargo l amp. Ci rcui t M1 al so powers the gl ove box
l amp and underhood l amp.
DOOR COURTESY LAMPS
When the BCM recei ves the courtesy l amp si gnal ,
i t broadcasts a message on the CCD bus. The mes-
sage si gnal s the Dri vers Door Modul e (DDM) and
Passenger Door Modul e (PDM). I n response, the
DDM and PDM power the courtesy l amps i n the
front doors on ci rcui t M1. Ci rcui t Z1 grounds the
courtesy l amps i n the front doors.
Ci rcui t F81 from the ci rcui t breaker i n cavi ty 2 of
the juncti on bl ock powers the DDM and PDM. Ci r-
cui t A250 from fuse 11 i n the PDC feeds ci rcui t F81
through the ci rcui t breaker.
ZG 8W - 44 INTERIOR LIGHTING 8W - 44 - 15
LIFTGATE COURTESY LAMP DISABLE
SWITCH
When cl osed, the l i ftgate di sabl e swi tch provi des
si gnal to the BCM on ci rcui t M4 i ndi cati ng a request
to di sabl e the courtesy l amps. To operate, al l the
doors must be cl osed wi th onl y the l i ftgate open.
Pushi ng on the l i ftgate l ens acti vates the swi tch.
Pushi ng on the l ense a second ti me deacti vates the
swi tch.
After recei vi ng the courtesy l amp di sabl e si gnal ,
the BCM turns off the courtesy l amps by de-energi z-
i ng the courtesy l amp rel ay.
GLOVE BOX LAMP
Ci rcui t A7 from 15 i n the Power Di stri buti on Cen-
ter (PDC) powers ci rcui t M1 through fuse 16 i n the
juncti on bl ock. Ci rcui t M1 powers the gl ove box
l amp. The l amp has a swi tch i n seri es whi ch when
cl osed, connects the l amp to ground on ci rcui t Z1.
UNDERHOOD LAMP
Ci rcui t M1 from fuse 16 i n the Power Di stri buti on
Center (PDC) feeds the underhood l amp. The l amp
contai ns a mercury swi tch whi ch connects the l amp
to ground on ci rcui t Z1 when the hood i s rai sed.
VISOR VANITY MIRRORS
Ci rcui t A7 from fuse 15 i n the Power Di stri buti on
Center (PDC) powers ci rcui t M1 through fuse 16 i n
the juncti on bl ock. Ci rcui t M1 feeds the vi sor vani ty
mi rror l amps. Each mi rror has a swi tch grounds the
l amps i n the mi rrors to ci rcui t Z1.
OVERHEAD CONSOLE LAMPS
Ci rcui t A7 from fuse 15 i n the Power Di stri buti on
Center (PDC) powers ci rcui t M1 through fuse 16 i n
the juncti on bl ock. Ci rcui t M1 feeds the overhead
consol e l amps.
Each overhead consol e l amp has a swi tch that con-
nects the l amps to ground on ci rcui t Z1. The l amps
are al so grounded when the Body Control Modul e
(BCM) energi zes the courtesy l amp rel ay to connect
ci rcui t M2 to ground on ci rcui t Z1.
DAY/NIGHT MIRROR
When the i gni ti on swi tch i s i n the RUN posi ti on, i t
connects ci rcui t A1 from fuse 8 i n the Power Di stri -
buti on Center (PDC) ci rcui t A22. Ci rcui t A22 powers
ci rcui t F83 through fuse 6 i n the juncti on bl ock. Ci r-
cui t F83 feeds the day/ni ght rear vi ew mi rror. Ci rcui t
Z1 grounds mi rror.
Ci rcui ts P112 and P114 connect from the day/ni ght
mi rror to the dri vers outsi de mi rror.
Ci rcui t L10 from the park/neutral swi tch si gnal s
the day/ni ght mi rror when the vehi cl e i s i n reverse.
The mi rror turns off when the vehi cl e i s i n reverse.
UNIVERSAL GARAGE DOOR OPENER
Ci rcui t A7 from fuse 15 i n the Power Di stri buti on
Center (PDC) powers ci rcui t M1 through fuse 16 i n
the juncti on bl ock. Ci rcui t M1 feeds the vi sor vani ty
mi rrors and the uni versal garage door opener. The
opener i s l ocated on the l eft vi sor. Ci rcui t Z1 provi des
ground for the opener.
8W - 44 - 16 8W - 44 INTERIOR LIGHTING ZG
DESCRIPTION AND OPERATION (Continued)
8W-45 BODY CONTROL MODULE
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Component Page
A/C Heater Control . . . . . . . . . . . . . . . . . . . 8W-45-9
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-45-9
Ash Lamp Recei ver . . . . . . . . . . . . . . . . . . 8W-45-10
Automati c Headl amp Li ght
Sensor/Vtss Led . . . . . . . . . . . . . . . . . . . 8W-45-4
Automati c Headl amp Rel ay . . . . . . . . . . . . . 8W-45-5
Automati c Temperature Control Modul e . . . 8W-45-9
Body Control Modul e . 8W-45-2, 3, 4, 5, 6, 7, 8, 9, 10
Brake Warni ng Swi tch . . . . . . . . . . . . . . . . 8W-45-9
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10
Ci rcui t Breaker 1 . . . . . . . . . . . . . . . . . . . . 8W-45-7
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7
Courtesy Lamp Rel ay . . . . . . . . . . . . . . . . . 8W-45-3
Data Li nk Connector . . . . . . . . . . . . . . . . . . 8W-45-2
Dayti me Runni ng Lamp Modul e . . . . . . . . . 8W-45-5
Fl oor Consol e Lamps . . . . . . . . . . . . . . . . . 8W-45-10
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-45-5
Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-45-6
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2, 3
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-11
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2, 6
G305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Headl amp Di mmer Swi tch . . . . . . . . . . . . . 8W-45-5
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-45-6
Hood Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-45-10
I ntermi ttent Wi per Rel ay . . . . . . . . . . . . . . 8W-45-7
I ntermi ttent Wi per Swi tch . . . . . . . . . . . . . 8W-45-7
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-45-2, 3, 4, 5, 7
Key-I n Swi tch/Hal o Lamp . . . . . . . . . . . . . . 8W-45-3
Left Front Cyl i nder Lock Swi tch . . . . . . . . . 8W-45-8
Left Front Door Ajar Swi tch . . . . . . . . . . . . 8W-45-8
Left Rear Door Ajar Swi tch . . . . . . . . . . . . . 8W-45-8
Component Page
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-45-11
Li ftgate Cyl i nder Lock Swi tch . . . . . . . . . . . 8W-45-8
Li ftgl ass Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-45-11
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . 8W-45-9
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-45-4
Power Di stri buti on Center . . . . . . . . . . . 8W-45-2, 3
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-45-3
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-45-9
Rear Wi per Modul e . . . . . . . . . . . . . . . . . . 8W-45-11
Ri ght Front Cyl i nder Lock Swi tch . . . . . . . . 8W-45-8
Ri ght Front Door Ajar Swi tch . . . . . . . . . . . 8W-45-8
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . . 8W-45-8
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-6
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
S219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-8
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-11
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-11
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Swi tch Pod . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10
ZG 8W - 45 BODY CONTROL MODULE 8W - 45 - 1
3
FUSE
10A
RUN-ACC A31
BLOCK
JUNCTION
A16
A15
15A
FUSE
18
V23
20
BR/PK
C1
16
C1 18
F99
18
OR
F99
20
OR
F99
20
OR
S101
H8 C236
BODY
CONTROL
MODULE
15 C2
FUSED
IGN.
(RUN-ACC) (RUN-ST)
IGN.
FUSED
8
C3 C2
24
GROUND GROUND GROUND
G304
S302
Z2
20
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z1
16
BK
Z1
14
BK
Z1
14
BK
S205
8 C307
C301 2
S202
CENTER
DISTRIBUTION
POWER
RUN-ST A21
C10
5
CONNECTOR
LINK
DATA
3 11
18
VT/BR
D1
19 C1
18
WT/BK
D2
20 C1
CCD
BUS
(-)
BUS
CCD
(+)
S204 S203
18
D1
VT/BR WT/BK
18
D2
CCD
(+)
BUS BUS
CCD
(-)
PAIR
TWISTED
(8W-12-4)
(8W-12-2)
(8W-10-13)
(8W-10-14)
(8W-10-15)
(8W-15-18)
(8W-15-18) (8W-15-18)
(8W-10-7)
(8W-10-3)
(8W-10-7)
8W - 45 - 2 8W-45 BODY CONTROL MODULE ZG-RHD
J978W-3 ZGR04501
3
FUSE
40A
2
9
14 C2
A900
12
OR/YL
REAR
WINDOW
DEFOGGER
RELAY
CONTROL
C14
20
WT/RD
BODY
CONTROL
MODULE
CONTROL
RELAY
HORN
GY/OR
20
X4
GY/OR
20
X4
13 C2
C10 7
1 C1
12
BATT A0
5
20A
FUSE
6
CENTER
DISTRIBUTION
POWER
JUNCTION
BLOCK
BK
20
Z1
S220
S216
BK
16
Z1
BK
18
Z1
LB
20
G26
KEY-IN
IGN.
SWITCH
SENSE CONTROL
RELAY
LAMP
COURTESY
2
1
BR/LG
20
M112
14 C1 C2 6
87 85
LAMP
HALO
SWITCH/
KEY-IN
HORN
RELAY
WINDOW
REAR
30
85
DEFOGGER
RELAY
LAMP
RELAY
COURTESY
A5
A3
3 C2
8 C10
(8W-44-8)
(8W-12-9)
(8W-48-2)
(8W-39-6)
(8W-41-2)
(8W-15-17)
(8W-15-17)
(8W-12-2)
(8W-10-3)
(8W-10-5)
(8W-10-3)
(8W-10-3)
ZG-RHD 8W-45 BODY CONTROL MODULE 8W - 45 - 3
ZGR04502 J978W-3
17
FUSE
15A
85 87
30 86
C10 10 9 C4
21 C2 8 C2
L79
20
TN
PARK
LAMP
RELAY
CONTROL
FUSED
B (+)
C4 8 11 C10
C1 17
OUTPUT
RELAY
LAMP
PARK
L90
20
DB/RD
20A
FUSE
7
DRIVER
LAMP
INDICATOR
VTSS
F75
18
VT
BATT A250 BATT A6
1
2 3 4
C1 23 2 C2 C2 9
ULTRALIGHT
SENSOR
DRIVER DRIVER
SENSOR
ULTRALIGHT
F75
18
VT
F75
18
VT
S201
G69
20
BK/LG
L109
20
WT
L110
20
OR/BK
SEAT
BELT
SWITCH
SENSE
14
C3
G10
20
LG/RD
G305
Z1
20
BK
Z1
12
BK
2
1
S304
SWITCH
BELT
SEAT
JUNCTION
BLOCK
MODULE
CONTROL
BODY
LED
AUTOMATIC
HEADLAMP
LIGHT
SENSOR/
VTSS
PARK
LAMP
RELAY
(8W-12-14)
(8W-12-8)
(8W-12-8)
(8W-15-15)
(8W-15-15)
(8W-10-10) (8W-10-11)
(8W-12-2)
8W - 45 - 4 8W-45 BODY CONTROL MODULE ZG-RHD
J978W-3 ZGR04503
C1 24
BODY
CONTROL
MODULE
DIMMER
SWITCH
HIGH
BEAM
OUTPUT OUTPUT
BEAM
LOW
SWITCH
DIMMER
9 C1 22 C2 C2 12
AUTOMATIC
HEADLAMP
RELAY
CONTROL
20
1 12
18
HEADLAMP
DIMMER
SWITCH
JUNCTION
BLOCK
L4
16
VT/OR
L3
16
RD/OR
F12 C234
L95
20
DG/YL
714
20
BK/OR
L3
16
RD/OR
L3
16
RD/OR
L3
16
RD/OR
S107
F2 C234
CONTROL
RELAY
LAMP
FOG
85
RELAY
FOG
LAMP
85
RELAY
HEADLAMP
AUTOMATIC
C10 C10
(8W-12-24)
(8W-50-2)
(8W-12-24)
(8W-50-6)
(8W-50-3)
(8W-12-2)
(8W-50-2)
ZG-RHD 8W-45 BODY CONTROL MODULE 8W - 45 - 5
ZGR04504 J978W-3
C2 20
BODY
CONTROL
MODULE
PANEL
LAMP
DIMMER
SWITCH
SIGNAL
OUTPUT
SWITCH
LAMP
FOG
15 C1 7 C1
6 8
6
4
5
1
2 0
3
13 2
5 FOG LAMP
4 DIMMER
3 AUTO
2 PARK
1 LOW
0 OFF
SWITCH
HEADLAMP
6 COURTESY LAMP
SENSE
SWITCH
HEADLAMP
AUTOMATIC
L35
20
BR/WT
707
20
BK/WT
L24
20
LB/RD
2
1
0
3
FOG
LAMP
SWITCH
MODULE
CONTROL
BODY
6
C1
3
M11
20
PK/LB
SWITCHED
COURTESY
LAMP
FEED
Z1
16
BK
S202
Z1
14
BK
2 C301
G304
Z1
14
BK
(8W-15-18)
(8W-15-18)
(8W-50-7)
(8W-50-5)
8W - 45 - 6 8W-45 BODY CONTROL MODULE ZG-RHD
J978W-3 ZGR04505
C1 1
BODY
CONTROL
MODULE
WINDSHIELD
WIPER
SWITCH
SIGNAL CONTROL
RELAY
WIPER
INTERMITTENT
23 C2 17 C2 C2 3
RADIO
CONTROL
MUX OUTPUT
SWITCH
WASHER
3
CLOCKSPRING
3
2
SENSE
MODE
SWITCH
WIPER
18 C2
1
MUX
CONTROL
RADIO
C5 C4
(IN PDC)
RELAY
WIPER
INTERMITTENT
C2 4
WIPER
PARK
SWITCH
SENSE
V50
18
LG/WT
V51
18
WT
V11
18
TN/BK
V66
18
VT/WT
V66
18
VT/WT
V66
16
VT/WT
V18
20
YL/LG
V18
20
YL/LG
709
20
RD/BK
13 20
C235
10 17
S120
RUN-ACC A31
JUNCTION
BLOCK
20A
1
BREAKER
CIRCUIT
12 7
8
4
SWITCH)
MULTI-FUNCTION
(PART OF
SWITCH
WIPER
INTERMITTENT
F86
16
LG/BK
V6
16
DB
V6
16
DB
S207
F18 C234
C1
F86 16 LG/RD
F86
16
LG/RD
F86
16
LG/RD
S122
C1 C4
C2
C3
INTERMITTENT
WIPER
SWITCH
(PART OF
MULTI-FUNCTION
SWITCH)
(8W-47-12)
(8W-53-3)
(8W-53-3)
(8W-12-2)
(8W-10-7)
(8W-12-4)
(8W-53-2)
(8W-12-4)
(8W-53-2)
ZG-RHD 8W-45 BODY CONTROL MODULE 8W - 45 - 7
ZGR04506 J978W-3
C3
13
C3 10
MODULE
CONTROL
BODY
LEFT
REAR
DOOR
AJAR
SWITCH SWITCH
AJAR
DOOR
FRONT
LEFT RIGHT
FRONT
DOOR
AJAR
SWITCH SWITCH
AJAR
DOOR
REAR
RIGHT
4
C3
9
C3
3
C3
G77
18
TN/OR
G75
18
TN
G74
18
TN/RD
G76
18
TN/YL
G71
20
VT/YL
S305
SWITCH
LOCK
CYLINDER
LIFTGATE
CYLINDER
FRONT
RIGHT LEFT
FRONT
CYLINDER
G71
20
VT/YL
G71
20
VT/YL
G71
20
VT/YL
G71
20
VT/YL
G71
20
VT/YL
G71
20
VT/YL
3
C321 14 C351 14 C334
1 1 1
SWITCH
LOCK
SWITCH
LOCK
LEFT
REAR
DOOR
AJAR
SWITCH
SENSE
DOOR
AJAR
SENSE
SWITCH
LEFT
FRONT
SWITCH
DOOR
SENSE
AJAR
FRONT
RIGHT
DOOR
AJAR
SENSE
SWITCH
RIGHT
REAR
VTSS
DISARM
SENSE
6
(8W-39-5) (8W-39-5)
(8W-39-5)
(8W-39-5)
8W - 45 - 8 8W-45 BODY CONTROL MODULE ZG-RHD
J978W-3 ZGR04507
C1 8
MODULE
CONTROL
BODY
RED
BRAKE
WARNING
LAMP
DRIVER
INPUT
SELECT
A/C
RETURN
SENSE
5 C1 2 C1 7 C2 2 C3
REAR
WINDOW
DEFOGGER
SWITCH
SENSE
SWITCH
DEFOGGER
WINDOW
REAR
C80
20
DB/YL
C90
20
LG
C2
7
CONTROL
A/C HEATER
C90
20
LG
C90
20
LG
A/C
SELECT
INPUT
INPUT
SELECT
A/C
C6
MODULE
CONTROL
TEMPERATURE
AUTOMATIC
2 1
D41
20
LG/WT
D41
20
LG/WT
S219
D41
20
LG/WT
D41
20
LG/WT
D41
20
LG/WT
D41
20
LG/WT
C8
20
DG/RD
C8
20
DG/RD
F11 C234
19
C235
11
SWITCH
BRAKE
PARK
S303
G9
20
GY/BK
G9
18
GY/BK
G9
20
GY/BK
2 C304
G9
16
GY/BK
1
BRAKE
WARNING
SWITCH
SENSOR
TEMPERATURE
AMBIENT
A/C
AMBIENT
TEMPERATURE
SENSOR
SIGNAL
ATC
MANUAL A/C
ATC MANUAL
A/C
(8W-40-6)
(8W-42-6)
(8W-42-4)
(8W-42-5)
(8W-48-2)
ZG-RHD 8W-45 BODY CONTROL MODULE 8W - 45 - 9
ZGR04508 J978W-3
C1
12
C3 6 16 C2
1
C3
POD
SWITCH
3 1
FLOOR
CONSOLE
LAMPS
INSTRUMENT
CLUSTER
10
S209
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
C
LAMP
CARGO
MODULE
CONTROL
BODY
G70
20
BR/TN
G70
20
BR/TN
4
C235
6
HOOD
SWITCH
(VTSS)
G78
20
TN/BK
A
(8W-45-11)
TO
S329
9
C321
M4
20
WT/LG
6 C302
3
LIFTGATE
AJAR
SWITCH
HOOD
SWITCH
AJAR
LIFTGATE
COURTESY
LAMP
DISABLE
DRIVER
LAMP
PANEL
LAMP
RECEIVER
ASH
S214
20
OR
E2 E2
20
OR
6
(8W-44-12)
(8W-44-12)
(8W-44-5)
(8W-44-11)
(8W-40-4)
(8W-44-11)
(8W-44-11)
8W - 45 - 10 8W-45 BODY CONTROL MODULE ZG-RHD
J978W-3 ZGR04509
S329
G78
20
TN/BK
3
C325
1
2
SWITCH
AJAR
LIFTGATE LIFTGLASS
1
SWITCH
AJAR
2
A
(8W-45-10)
C321
FROM
G78
TN/BK
20
TN/BK
G78
20 20
G78
TN/BK
REAR
WIPER
MODULE
6
Z1
BK
20
12
BK
Z1
20
BK
Z1
BK
12
Z1
S328
12
BK
Z1
G300
S328
2
(8W-15-11)
(8W-15-10)
(8W-53-4)
ZG-RHD 8W-45 BODY CONTROL MODULE 8W - 45 - 11
ZGR04510 J978W-3
8W-45 BODY CONTROL MODULE
INDEX
page page
DESCRIPTION AND OPERATION
A/C SELECT SWITCH . . . . . . . . . . . . . . . . . . . . 12
AJAR CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AMBIENT TEMPERATURE SENSOR . . . . . . . . . 12
AUTO HEADLAMPS . . . . . . . . . . . . . . . . . . . . . 13
COURTESY LAMP SWITCH . . . . . . . . . . . . . . . 12
ENGINE TEMPERATURE CRITICAL CHIME . . . 13
IGNITION SWITCH SENSE . . . . . . . . . . . . . . . . 13
INSTRUMENT PANEL DIMMING . . . . . . . . . . . . 13
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 12
KEY-IN IGNITION CHIME . . . . . . . . . . . . . . . . . 13
LIFTGATE COURTESY LAMP DISABLE
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LOW FUEL WARNING LAMP ANNOUNCEMENT
CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LOW OIL PRESSURE WARNING CHIME . . . . . . 13
PARK LAMP SWITCH SENSE . . . . . . . . . . . . . . 13
SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION AND OPERATION
INTRODUCTION
The Body Control Modul e (BCM) used i n thi s vehi -
cl e provi des a communi cati on i nterface wi th other
control l ers and modul es. The BCM al so control s var-
i ous vehi cl e functi ons. Ci rcui t operati on of speci fi c
systems or components control l ed by the BCM are
found i n wi ri ng di agram secti on coveri ng the compo-
nent or system.
Thi s secti on of the wi ri ng di agrams provi des an
overvi ew of the functi ons control l ed or supported by
the BCM. The BCM provi des or supports the fol l ow-
i ng features:
A/C Sel ect Swi tch Status
Ambi ent Temperature
Automati c Funeral Mode
Automati c Headl amp Control
Chi me
Courtesy Lamps wi th Ti me Out
Door, Hood or Li ftgate Ajar Status
Door Lock I nhi bi t
El ectroni c Odometer
El ectroni c Vehi cl e I nformati on Center
Fog Lamp Control
Headl amp Del ay
Hi gh Beam I ndi cator
I l l umi nated Entry
I nstrument Panel Di mmi ng
I ntermi ttent Wi per Control
Li ftgate Courtesy Lamp Di sabl e
Mechani cal I nstrument Cl uster
Rear Wi ndow Defogger Control
Remote Radi o Control
Seat Bel t Remi nder
Speed Sensi ti ve I ntermi ttent Wi pe Control
Vehi cl e Theft Securi ty System
The BCM communi cates wi th the fol l owi ng control -
l ers and modul es over the CCD bus:
Automati c Temperature Control (ATC) Modul e
Compass (Overhead Consol e)
Dri ver Door Modul e (DDM)
Mechani cal I nstrument Cl uster
Memory Seat Modul e
Passenger Door Modul e (PDM)
Powertrai n Control Modul e
Vehi cl e I nformati on Center
Radi o
Ci rcui t A250 from fuse 11 i n the Power Di stri bu-
ti on Center (PDC) powers ci rcui t F75 through fuse 7
i n the juncti on bl ock. Ci rcui t F75 suppl i es battery
vol tage to the BCM. Ci rcui ts Z1 and Z2 provi de
ground for the BCM.
A/C SELECT SWITCH
I f the vehi cl e i s equi pped wi th Automati c Temper-
ature Control (ATC), the Automati c Temperature
Control Modul e sends the A/C sel ect swi tch to the
Body Control Modul e (BCM) on ci rcui t C90. I f the
vehi cl e has manual A/C, the A/C-heater control
swi tch sends the A/C sel ect si gnal to the BCM on ci r-
cui t C90.
AMBIENT TEMPERATURE SENSOR
The ambi ent ai r temperature sensor i s a vari abl e
resi stor. As ambi ent (outsi de) temperature vari es, the
resi stance i n the sensor changes. Ci rcui t C8 from the
Body Control Modul e (BCM) suppl i es power to the
sensor. Ci rcui t D41 provi des the sensor si gnal to the
BCM.
COURTESY LAMP SWITCH
When the courtesy l amp swi tch i nsi de the head-
l amp swi tch cl oses, i t compl etes a path to ground for
ci rcui t M11 from the Body Control Modul e (BCM).
The BCM energi zes the courtesy l amp rel ay i n the
juncti on bl ock to power the courtesy l amps. Refer to
secti on 8W-44.
8W - 45 - 12 8W - 45 BODY CONTROL MODULE ZG
LIFTGATE COURTESY LAMP DISABLE SWITCH
When the courtesy l amp di sabl e swi tch cl oses, i t
provi des battery vol tage to the Body Control Modul e
(BCM) on ci rcui t M4.
AUTO HEADLAMPS
When the operator puts the headl amp swi tch i n
the AUTO posi ti on, the auto headl amp swi tch cl oses
and connects ci rcui t L24 from the Body Control Mod-
ul e to ground. Thi s si gnal s the BCM to operate the
headl amps based on the ul tral i ght sensor i nput. The
BCM powers the ul tral i ght sensor on ci rcui t L110.
Ci rcui t L109 provi des the si gnal from the sensor to
the BCM.
PARK LAMP SWITCH SENSE
When the operator puts the headl amp swi tch i n
the park l amp posi ti on, the park l amp swi tch cl oses
and ci rcui t L90 powers the parki ng l amps. Ci rcui t
L90 al so provi des an i nput to the Body Control Mod-
ul e (BCM). The BCM moni tors the L90 ci rcui t and
ci rcui t 707 from the di mmer swi tch to determi ne
i nstrument panel l amp i ntensi ty
INSTRUMENT PANEL DIMMING
On ci rcui t 707 from the di mmer swi tch i n the
headl amp swi tch, the Body Control Modul e (BCM)
determi nes sel ected i ntensi ty for the i nstrument
panel l amps. The BCM al so transmi ts a si gnal repre-
senti ng requi red l amp i ntensi ty over the CCD bus.
After recei vi ng the si gnal from the CCD bus, al l
other di spl ay modul es update thei r bri ghtness l evel .
IGNITION SWITCH SENSE
On ci rcui t V23, the Body Control Modul e (BCM)
senses when the i gni ti on swi tch i s i n the ACCES-
SORY or RUN posi ti on. The BCM senses when the
i gni ti on swi tch i s i n the START or RUN posi ti on on
ci rcui t F99.
AJAR CHIME
On model s equi pped wi th a Vehi cl e I nformati on
Center (VI C), the Body Control Modul e (BCM)
sounds an audi bl e chi me when the vehi cl e i s movi ng
i f one of the doors, the hood, or l i ftgate opens. The
BCM al so si gnal s the VI C over the CCD bus. The
VI C then di spl ays whi ch component i s ajar.
KEY-IN IGNITION CHIME
When the key i s i nserted i nto the i gni ti on swi tch,
the key-i n swi tch cl oses and connects ci rcui t G26
from the Body Control Modul e to ground on ci rcui t
Z1. When the key-i n swi tch cl oses, the BCM sounds
an audi bl e fast rate chi me.
SEAT BELT SWITCH
The seat bel t swi tch cl oses when the seat bel t i s
not buckl ed. When cl osed, the swi tch connects ci rcui t
G10 from the Body Control Modul e (BCM) to ground
on ci rcui t Z1. I f the swi tch i s cl osed whi l e the i gni -
ti on swi tch i s ON, the BCM sounds an audi bl e warn-
i ng chi me.
LOW OIL PRESSURE WARNING CHIME
When oi l pressure drops bel ow a cal i brated l evel ,
the Body Control Modul e (BCM) sounds an audi bl e
chi me to al ert the operator. The BCM recei ves the
l ow oi l pressure si gnal on the CCD bus.
ENGINE TEMPERATURE CRITICAL CHIME
When engi ne temperature exceeds a pre-deter-
mi ned temperature, the Body Control Modul e (BCM)
sounds an audi bl e chi me. The Powertrai n Control
Modul e (PCM) broadcasts engi ne cool ant tempera-
ture to the BCM on the CCD bus.
LOW FUEL WARNING LAMP ANNOUNCEMENT
CHIME
The Body Control Modul e (BCM) sounds an audi -
bl e chi me when the l ow fuel warni ng l amp i l l umi -
nates.
ZG 8W - 45 BODY CONTROL MODULE 8W - 45 - 13
DESCRIPTION AND OPERATION (Continued)
8W-46 MESSAGE CENTER
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Page
Body Control Modul e . . . . . . . . . . . . . . 8W-46-2, 4, 7
El ectroni c Fl asher . . . . . . . . . . . . . . . . . . . . 8W-46-6
Engi ne Cool ant Level Sensor . . . . . . . . . . . 8W-46-6
Four Wheel Dri ve Swi tch . . . . . . . . . . . . 8W-46-3, 5
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-6
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-3, 5
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-6
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-6
G118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-6
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-6
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
Graphi c Di spl ay Modul e . . . . . . . . . . . . . 8W-46-2, 3
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-46-6
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-46-2, 3, 4, 5, 6
Lamp Outage Modul e . . . . . . . . . . . . . . . . . 8W-46-6
Power Di stri buti on Center . . . . . . . . . . . 8W-46-2, 4
Component Page
Powertrai n Control Modul e . . . . . . . . . . . 8W-46-6, 7
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-6
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-6
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-3, 5
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-7
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-7
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2, 4
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-6
Turn Si gnal /Hazard Warni ng Swi tch . . . . . . 8W-46-6
Vehi cl e I nformati on Center . . . . . . . 8W-46-4, 5, 6, 7
Wi per Fl ui d Level Sensor . . . . . . . . . . . . . . 8W-46-6
ZG 8W - 46 MESSAGE CENTER 8W - 46 - 1
15
FUSE
40A
28
BATT A0
21
2
5
15A
FUSE
20 6
FUSE
15A
1
C2
C9 C8
A7
12
YL/RD
2
3
16
F60
20
RD/WT
20
10
FUSED
IGN.
(RUN)
FUSED
B (+)
GROUND
PANEL
LAMP
DRIVER
GROUND
F83
18
YL/DG
F83
18
YL/DG
S212
E2
20
OR
E2
20
OR
E2
20
OR
S214
S209
PANEL
LAMP
DRIVER
BODY
CONTROL
MODULE
Z2
20
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z1
20
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
S205
8 C307
S302
2 C301
G304
S202
S216
MODULE
DISPLAY
GRAPHIC
CENTER
DISTRIBUTION
POWER
JUNCTION
BLOCK
RUN A22
16
C2
(8W-10-7)
(8W-12-2)
(8W-10-3)
(8W-10-3)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-15-18)
(8W-45-2)
(8W-15-18)
(8W-45-10)
(8W-44-11)
(8W-44-12) (8W-12-6)
(8W-12-6) (8W-12-16)
(8W-10-12)
8W - 46 - 2 8W-46 MESSAGE CENTER
STANDARD
ZG-RHD
J978W-3 ZGR04601
2
3
2
7
6
LAMP
2WD
17
4WD
LAMP
PART
TIME
FULL
TIME LOW
18 19 14 15
6 C4 C5 C5 C4
C3 C1
T19
20
YL/BK
107
20
BK/RD
G42
20
LB/RD
G28
20
LG/OR
G28
20
LG/OR
107
20
BK/RD
A B C212
3
1
4 2
G28
20
LG/OR
G28
20
LG/OR
T107
20
BK/RD
T107
20
BK/RD
8 C131
10 9 C132
T106
20
GY/OR
T106
20
GY/OR
C132 9
T106
20
GY/OR
G105
Z12
20
BK/TN
Z12
16
BK/TN
S130
1
2
3
4
MODULE
DISPLAY
GRAPHIC
JUNCTION
BLOCK
4 NEUTRAL
2 P/T 4WD
3 F/T 4WD
FOUR
WHEEL
DRIVE
SWITCH
1 LOW 4WD
(8W-15-7)
(8W-15-7)
(8W-12-2)
ZG-RHD 8W-46 MESSAGE CENTER
STANDARD
8W - 46 - 3
ZGR04602 J978W-3
15
FUSE
40A
28
BATT A0
21
2
5
15A
FUSE
20 6
FUSE
15A
1
C2
C9 C8
A7
12
YL/RD
2
3
16
F60
20
RD/WT
20
10
FUSED
IGN.
(RUN)
FUSED
B (+)
GROUND
PANEL
LAMP
DRIVER
GROUND
F83
18
YL/DG
F83
18
YL/DG
S212
E2
20
OR
E2
20
OR
E2
20
OR
S214
S209
PANEL
LAMP
DRIVER
BODY
CONTROL
MODULE
Z2
20
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z1
20
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
S205
8 C307
S302
2 C301
G304
S202
S216
CENTER
INFORMATION
VEHICLE
CENTER
DISTRIBUTION
POWER
JUNCTION
BLOCK
RUN A22
16
C2
(8W-12-2)
(8W-10-7)
(8W-10-3)
(8W-10-3)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-15-18)
(8W-15-18)
(8W-45-10)
(8W-44-11)
(8W-44-12) (8W-12-6)
(8W-12-6) (8W-12-16)
(8W-10-12)
8W - 46 - 4 8W-46 MESSAGE CENTER
OVERHEAD CONSOLE
ZG-RHD
J978W-3 ZGR04603
2
3
2
7
6
LAMP
2WD
17
4WD
LAMP
PART
TIME
FULL
TIME LOW
18 19 14 15
6 C4 C5 C5 C4
C3 C1
T19
20
YL/BK
107
20
BK/RD
G42
20
LB/RD
G28
20
LG/OR
G28
20
LG/OR
107
20
BK/RD
A B C212
3
1
4 2
G28
20
LG/OR
G28
20
LG/OR
T107
20
BK/RD
T107
20
BK/RD
8 C131
10 9 C132
T106
20
GY/OR
T106
20
GY/OR
C132 9
T106
20
GY/OR
G105
Z12
20
BK/TN
Z12
16
BK/TN
S130
1
2
3
4
CENTER
INFORMATION
VEHICLE
JUNCTION
BLOCK
4 NEUTRAL
2 P/T 4WD
3 F/T 4WD
FOUR
WHEEL
DRIVE
SWITCH
1 LOW 4WD
(8W-15-7)
(8W-15-7)
(8W-12-2)
ZG-RHD 8W-46 MESSAGE CENTER
OVERHEAD CONSOLE
8W - 46 - 5
ZGR04604 J978W-3
11
13 5
4
PARK
LAMP
RELAY
OUTPUT
SIGNAL
TURN
SENSE
LEVEL
COOLANT
ENGINE WASHER
FLUID
LEVEL
SENSE FAILURE
LAMP
REAR
HEADLAMP
SWITCH
0 OFF
1 LOW
2 PARK
16
15
17
FUSE
15A
11
BATT A6
C9
366
16
PK/OR
0
2
1
3
C8
5
C8 10
L90
20
DB/RD
L90
20
DB/RD
17
L5
18
OR/BK
1
G106 G109
Z1
14
BK
Z1
16
BK
S104
Z2
16
BK
Z1
12
BK
S121
G18
20
PK/BK
G18
16
PK/BK
G29
20
BK/TN
G29
16
BK/TN
F6 F7 C234
3 AUTO
2
1
SENSOR
LEVEL
COOLANT
ENGINE
1
2
WIPER
FLUID
LEVEL
SENSOR
G46
20
BK/LB
5 C307
LAMP
OUTAGE
MODULE OTHERS
G302
S314
Z1
12
BK
Z1
18
BK
G46
20
LB/BK
G46
20
LB/BK
9
LAMP
OUTAGE
MODULE
REAR
LAMP
OUT
INDICATOR
DRIVER
9 C316
VEHICLE
INFORMATION
CENTER
JUNCTION
BLOCK
JUNCTION
BLOCK
SWITCH
WARNING
HAZARD
SIGNAL/
TURN
OR/BK
L5
1 C5
18
2
ELECTRONIC
FLASHER
C1
DIESEL GAS
PK/DB
G118
54
MODULE
CONTROL
POWERTRAIN
C4
20
8 C131
G118
PK/DB
20
(8W-30-29)
(8W-52-6)
(8W-52-2)
(8W-52-4)
(8W-52-6)
(8W-12-2)
(8W-10-11)
(8W-12-2)
(8W-51-5)
(8W-15-12)
(8W-15-12)
(8W-50-2)
(8W-50-5)
(8W-50-7)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-15-7)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-15-7)
(8W-12-14)
8W - 46 - 6 8W-46 MESSAGE CENTER
OVERHEAD CONSOLE
ZG-RHD
J978W-3 ZGR04605
7 8
VEHICLE
INFORMATION
CENTER
C1 19
MODULE
CONTROL
BODY
C1 20
D1
18
VT/BR
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
C3
C30 C28
C3
S203 S204
D2
18
WT/BK
D2
18
WT/BK
D1
18
VT/BR
D1
18
VT/BR
19 20
C235
10 11
CCD
BUS
(-) (+)
BUS
CCD
CCD
BUS
(+)
CCD
BUS
(-)
MODULE
CONTROL
POWERTRAIN
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
(8W-30-18)
(8W-30-19)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-45-2)
ZG-RHD 8W-46 MESSAGE CENTER
OVERHEAD CONSOLE
8W - 46 - 7
ZGR04606 J978W-3
8W-46 MESSAGE CENTER
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION AND OPERATION
GRAPHIC DISPLAY MODULE . . . . . . . . . . . . . . . 8
VEHICLE INFORMATION CENTER . . . . . . . . . . . 8
GENERAL INFORMATION
INTRODUCTION
Each four-wheel dri ve equi pped Grand Cherokee i s
equi pped wi th a four-wheel dri ve Graphi c Di spl ay
Modul e (GDM). The GDM i s l ocated at the bottom of
the i nstrument panel center stack. The GDM di s-
pl ays transfer case mode sel ecti on.
Some vehi cl e are equi pped wi th an opti onal Vehi cl e
I nformati on Center (VI C). The VI C has several func-
ti ons:
Di spl ay current ti me and date.
Moni tor speci fi c vehi cl e operati ng systems and
al ert the dri ver i f a mal functi on occurs.
Di spl ay servi ce remi nder or i ndi cate di stance to
servi ce.
Di spl ay 2WD/4WD transfer case modes of oper-
ati on.
DESCRIPTION AND OPERATION
GRAPHIC DISPLAY MODULE
Several fuses suppl y power to the Graphi c Di spl ay
Modul e (GDM). When the i gni ti on swi tch i s i n the
RUN posi ti on i t connects ci rcui t A1 from fuse 8 i n
the PDC to ci rcui t A22. Ci rcui t A22 feeds ci rcui t F83
through fuse 6 i n the juncti on bl ock. Ci rcui t F83 sup-
pl i es vol tage to the GDM.
Ci rcui t A7 from fuse 15 i n the PDC powers ci rcui t
F60 through fuse 20 i n the juncti on bl ock. Ci rcui ts
A7 and F60 are HOT at al l ti mes. Ci rcui t F60 feeds
the GDM. Ci rcui ts Z1 and Z2 provi de ground for the
GDM.
TRANSFER CASE RANGE DISPLAY
When the transfer case i s i n ei ther 4WD Low, Part
Ti me 4WD, or Ful l Ti me i t connects ci rcui t G28 from
the Graphi c Di spl ay Modul e (GDM) to ground on ci r-
cui t Z12. I n response, the GDM i l l umi nates the 4WD
di spl ay.
When the transfer case swi tch i s i n 4WD Low, i t
connects ci rcui t G28 from the GDM to ground on ci r-
cui t Z12. I n addi ti on to i l l umi nati ng the 4WD di s-
pl ay, the GDM al so i l l umi nates the LOW di spl ay.
When the transfer case swi tch i s i n Part Ti me
4WD posi ti on, i t connects ci rcui t T107 from the GDM
to ground on ci rcui t Z12. I n addi ti on to i l l umi nati ng
the 4WD di spl ay, the GDM al so i l l umi nates the
PART TI ME di spl ay.
When the transfer case swi tch i s i n Ful l Ti me 4WD
posi ti on, i t connects ci rcui t T106 from the GDM to
ground on ci rcui t Z12. I n addi ti on to i l l umi nati ng the
4WD di spl ay, the GDM al so i l l umi nates the FULL
TI ME di spl ay.
VEHICLE INFORMATION CENTER
Several fuses suppl y power to the Vehi cl e I nforma-
ti on Center (VI C). When the i gni ti on swi tch i s i n the
RUN posi ti on i t connects ci rcui t A1 from fuse 8 i n
the PDC to ci rcui t A22. Ci rcui t A22 feeds ci rcui t F83
through fuse 6 i n the juncti on bl ock. Ci rcui t F83 sup-
pl i es vol tage to the VI C.
Ci rcui t A7 from fuse 15 i n the PDC powers ci rcui t
F60 through fuse 20 i n the juncti on bl ock. Ci rcui ts
A7 and F60 are HOT at al l ti mes. Ci rcui t F60 feeds
the VI C.
Ci rcui t A6 from fuse 13 i n the PDC powers ci rcui t
366 through fuse 17 i n the juncti on bl ock. Ci rcui t 366
connects to the headl amp swi tch. When the head-
l amp swi tch i s i n the PARK or LOW posi ti on, i t con-
nects ci rcui t 366 to ci rcui t L90. Ci rcui t L90 connects
to the VI C. Ci rcui t E2 from the Body Control Modul e
(BCM) powers the i l l umi nati on l amps i n the VI C.
Ci rcui ts Z1 and Z2 provi de ground for the VI C.
TRANSFER CASE RANGE DISPLAY
When the transfer case i s i n ei ther 4WD Low, Part
Ti me 4WD, or Ful l Ti me i t connects ci rcui t G28 from
the Vehi cl e I nformati on Center (VI C) to ground on
ci rcui t Z12. I n response, the VI C i l l umi nates the
4WD di spl ay.
When the transfer case swi tch i s i n 4WD Low, i t
connects ci rcui t G28 from the VI C to ground on ci r-
cui t Z12. I n addi ti on to i l l umi nati ng the 4WD di s-
pl ay, the VI C al so i l l umi nates the LOW di spl ay.
8W - 46 - 8 8W - 46 MESSAGE CENTER ZG
When the transfer case swi tch i s i n Part Ti me
4WD posi ti on, i t connects ci rcui t T107 from the VI C
to ground on ci rcui t Z12. I n addi ti on to i l l umi nati ng
the 4WD di spl ay, the VI C al so i l l umi nates the PART
TI ME di spl ay.
When the transfer case swi tch i s i n Ful l Ti me 4WD
posi ti on, i t connects ci rcui t T106 from the VI C to
ground on ci rcui t Z12. I n addi ti on to i l l umi nati ng the
4WD di spl ay, the VI C al so i l l umi nates the FULL
TI ME di spl ay.
LAMP OUTAGE
Ci rcui t G46 connects from the Lamp Outage Mod-
ul e (LOM) to the Vehi cl e I nformati on Center (VI C).
Ci rcui t G46 suppl i es the rear l amp out si gnal to the
VI C.
LOW WASHER FLUID WARNING
When the l ow washer fl ui d swi tch cl oses, i t con-
nects ci rcui t G29 from the VI C to ground on ci rcui t
Z1. The VI C di spl ays the Low Washer Fl ui d warni ng
when the swi tch cl oses.
LOW ENGINE COOLANT WARNING
When the engi ne cool ant l evel swi tch cl oses, i t con-
nects ci rcui t G18 from the VI C to ground on ci rcui t
Z1. The VI C di spl ays the Low Cool ant Level warni ng
when the swi tch cl oses.
DOOR AJ AR AND LIFTGATE AJ AR DISPLAYS
Each door and the l i ftgate have an ajar swi tch that
connects to the Body Control Modul e (BCM). The
BCM senses when the l i ftgate or a door opens, and
sends the a si gnal to the VI C on the CCD bus. I n
response, the VI C di spl ays whi ch door i s open. The
VI C communi cates wi th the BCM over the CCD bus
on ci rcui ts D1 and D2.
ZG 8W - 46 MESSAGE CENTER 8W - 46 - 9
DESCRIPTION AND OPERATION (Continued)
8W-47 AUDIO SYSTEM
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Component Page
Antenna . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 9, 10
Body Control Modul e . . . . . . . . . . . . . . . 8W-47-2, 12
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-12
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-9, 10
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
G303 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 9, 10
G304 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4, 12
Juncti on Bl ock . . . . . . . . . . . . . . 8W-47-2, 3, 4, 9, 10
Left Front Door Speaker . . . . . . . . . . . 8W-47-5, 6, 8
Left I nstrument Panel Speaker . . . . . . . . 8W-47-5, 6
Left Radi o Remote Swi tch . . . . . . . . . . . . . 8W-47-12
Left Rear Door Speaker . . . . . . . . . . . 8W-47-7, 8, 11
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-47-2
Power Ampl i fi er . . . 8W-47-3, 4, 5, 6, 7, 9, 10, 11, 13
Power Antenna . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4
Power Antenna Rel ay . . . . . . . . . . . . . . . 8W-47-3, 4
Powertrai n Control Modul e . . . . . . . . . . . . 8W-47-12
Radi o . . . . . . . . . . . . . . . . 8W-47-2, 3, 4, 8, 9, 10, 12
Rear Speaker . . . . . . . . . . . . . . . . . . . . 8W-47-11, 13
Component Page
Ri ght Front Door Speaker . . . . . . . . . . 8W-47-5, 6, 8
Ri ght I nstrument Panel Speaker . . . . . . . 8W-47-5, 6
Ri ght Radi o Remote Swi tch . . . . . . . . . . . . 8W-47-12
Ri ght Rear Door Speaker . . . . . . . . . . 8W-47-7, 8, 11
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 12
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 12
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-12
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3, 4
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-12
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-9, 10
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-9, 10
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
Vehi cl e Speed Control /Horn Swi tch . . . . . . 8W-47-12
ZG 8W - 47 AUDIO SYSTEM 8W - 47 - 1
1
C7 C9
10
15A
FUSE
17
10A
FUSE
1
15A
FUSE
20
4
C8
BLOCK
JUNCTION
BATT A6 RUN-ACC A31 BATT A7
L90
20
DB/RD
X12
18
RD/GY
F60
20
RD/WT
RADIO
4 C1 C1 6 7 C1
FUSED
B (+) COAX
ANTENNA PANEL
LAMP
RELAY (RUN-ACC)
IGN.
FUSED
OUTPUT
30
87
ANTENNA
C2
1
C1 19
S204
D1
18
VT/BR
D1
18
VT/BR
20 C1
2
C2
S203
D2
18
WT/BK
D2
18
WT/BK
C2 16
C1
5
E2
20
OR
E2
20
OR
E2
20
OR
S214
S209
MODULE
CONTROL
BODY
CCD
BUS
(+) (-)
BUS
CCD PANEL
LAMP
DRIVER
PANEL
LAMP
DRIVER
CCD
BUS
(+)
BUS
CCD
(-)
9
C305
Z5
16
BK
Z5
14
BK/LB
G303
PAIR
TWISTED
TWISTED
PAIR
12
PARK
LAMP
RELAY
(8W-12-14) (8W-12-3) (8W-12-16)
(8W-12-2)
(8W-10-9) (8W-10-11) (8W-10-12)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-44-12)
(8W-44-11)
(8W-45-2)
(8W-45-10) (8W-15-13)
(8W-50-7)
(8W-50-8)
8W - 47 - 2 8W-47 AUDIO SYSTEM ZG-RHD
J978W-3 ZGR04701
C1
14
RADIO
12V
OUTPUT
POWER
AMPLIFIER
OUTPUT
12V
RADIO
1
C3
RADIO
C11
3
C14 4
4 5 6 1
3 2
1 2 1 2
1 DOWN
(EXPORT)
RELAY
ANTENNA
POWER
5 C5
15A
FUSE
13
BATT A7
2
C11
1
C11 C5
4
X60
18
DG/RD
X60
20
DG/RD
M
POWER
ANTENNA
(EXPORT)
1 DOWN
X14
20
WT
X16
20
GY
X17
20
DG
G304
Z1
18
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
C301
S220
S216
S202
COAX
ANTENNA
RADIO
ANTENNA
COAX
2
1 2
JUNCTION
BLOCK
2 UP
2 UP
(8W-10-12)
(8W-12-2)
(8W-15-18)
(8W-15-17)
(8W-15-17)
(8W-15-18)
(8W-12-11)
ZG-RHD 8W-47 AUDIO SYSTEM
LTD AND POWER AMP
8W - 47 - 3
ZGR04702 J978W-3
C1
8
RADIO
12V
OUTPUT
POWER
AMPLIFIER
(PREMIUM)
OUTPUT
12V
RADIO
1
C3
RADIO
C11
3
C14 4
4 5 6 1
3 2
1 2 1 2
1 DOWN
(EXPORT)
RELAY
ANTENNA
POWER
5 C5
15A
FUSE
13
BATT A7
2
C11
1
C11 C5
4
X60
18
DG/RD
X60
20
DG/RD
M
POWER
ANTENNA
(EXPORT)
1 DOWN
X14
20
WT
X16
20
GY
X17
20
DG
G304
Z1
18
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
C301
S220
S216
S202
COAX
ANTENNA
RADIO
ANTENNA
COAX
2
1 2
JUNCTION
BLOCK
2 UP
2 UP
(8W-12-2)
(8W-10-12)
(8W-15-18)
(8W-15-17)
(8W-15-17)
(8W-15-18)
(8W-12-11)
8W - 47 - 4 8W-47 AUDIO SYSTEM
PREMIUM
ZG-RHD
J978W-3 ZGR04703
C2
3
POWER
AMPLIFIER
X87
16
LG/RD
X87
16
LG/RD
X87
16
LG/RD
6 C334 14 C307
X87
20
LG/RD
S300
X53
20
DG
SPEAKER
PANEL
INSTRUMENT
LEFT
SPEAKER
DOOR
FRONT
LEFT
X55
20
BR/RD
8 C334
S301
X85
16
LG/BK
X85
16
LG/BK
13 C307
X85
20
LG/BK
C2 9
X85
16
LG/BK
POWER
AMPLIFIER
AMPLIFIED
LEFT
FRONT
(-)
AMPLIFIED
LEFT
FRONT
(+)
LB/DG
16
X80
2 C1
LB/BK
20
X80
C307 2
LB/DG
16
X80
LB/BK
16
X80
S319
C351 8
DB/RD
20
X56
RIGHT
FRONT
DOOR
SPEAKER
RIGHT
INSTRUMENT
PANEL
SPEAKER
VT
20
X54
S335
LB/RD
20
X82
C307 1 C351 6
LB/RD
16
X82
LB/RD
16
X82
LB/RD
16
X82
1
C1
(-)
FRONT
RIGHT
AMPLIFIED
(+)
FRONT
RIGHT
AMPLIFIED
A
B B
A
B
A
B
A
ZG-RHD 8W-47 AUDIO SYSTEM
PREMIUM
8W - 47 - 5
ZGR04704 J978W-3
C2
12
POWER
AMPLIFIER
X87
16
LG/RD
X87
16
LG/RD
X87
16
LG/RD
6 C334 14 C307
X87
20
LG/RD
S300
X53
20
DG
SPEAKER
PANEL
INSTRUMENT
LEFT
SPEAKER
DOOR
FRONT
LEFT
X55
20
BR/RD
8 C334
S301
X85
16
LG/BK
X85
16
LG/BK
13 C307
X85
20
LG/BK
C2 11
X85
16
LG/BK
POWER
AMPLIFIER
AMPLIFIED
LEFT
FRONT
(-)
AMPLIFIED
LEFT
FRONT
(+)
LB/DG
16
X80
2 C2
LB/RD
20
X80
C307 2
LB/DG
16
X80
LB/DG
16
X80
S319
C351 8
DB/RD
20
X56
RIGHT
FRONT
DOOR
SPEAKER
RIGHT
INSTRUMENT
PANEL
SPEAKER
VT
20
X54
S335
LB/BK
20
X82
C307 1 C351 6
LB/RD
16
X82
LB/RD
16
X82
LB/RD
16
X82
1
C2
(-)
FRONT
RIGHT
AMPLIFIED
(+)
FRONT
RIGHT
AMPLIFIED
A
B B
A
B
A
B
A
8W - 47 - 6 8W-47 AUDIO SYSTEM
LTD
ZG-RHD
J978W-3 ZGR04705
7 C2 C1 9
AMPLIFIER
POWER
B
A
B
A
X58
20
DB/OR
X91
16
WT/BK
X92
16
TN/BK
X58
20
DB/OR
SPEAKER
DOOR
REAR
LEFT RIGHT
REAR
DOOR
SPEAKER
C343 C345
C2
1
POWER
AMPLIFIER
A C343
X93
16
WT/RD
X52
20
DB/WT
3
C1
X94
16
TN/RD
A C345
X52
20
DB/WT
AMPLIFIED
LEFT
REAR
(+) (+)
REAR
RIGHT
AMPLIFIED
B B
AMPLIFIED
RIGHT
REAR
(-) (-)
REAR
RIGHT
AMPLIFIED
ZG-RHD 8W-47 AUDIO SYSTEM
PREMIUM
8W - 47 - 7
ZGR04706 J978W-3
C3 2
LEFT
REAR
(+)
REAR
LEFT
6 C3 C3 7
RIGHT
REAR REAR
RIGHT
3 C3
B
A
B
A
X51
16
BR/YL
X52
20
BR/YL
X58
20
BR/LB
X57
16
BR/LB
X52
16
DB/WT
X52
20
DB/WT
X58
16
DB/OR
X58
20
DB/OR
SPEAKER
DOOR
REAR
LEFT RIGHT
REAR
DOOR
SPEAKER
C343 C345
(-) (+) (-)
RADIO
(-)
C351
RIGHT
FRONT
DOOR
SPEAKER
DB
16
X56
DB/RD
20
X56
VT
20
X54
VT
16
X54
A
B
C1 3
RIGHT
FRONT
(+)
FRONT
RIGHT
5 C3 C3 4
LEFT
FRONT
(+)
FRONT
LEFT
2 C1
B
A
X53
16
DG
X53
20
DG
X55
20
BR/RD
X55
16
BR/RD
DOOR
FRONT
LEFT
C334
(-)
SPEAKER
C305
X53
20
DG
X55
20
BR/RD
X54
20
VT/YL
X56
20
DB
X51
20
BR/YL
X57
20
BR/LB
X52
20
DB/WT
X58
20
DB/OR
6 6 A A 8 8 B B
14 13 11 10 8 7 5 6
1 2 14 13 11 10 8 7
PAIR
TWISTED
PAIR
TWISTED TWISTED
PAIR
TWISTED
PAIR
PAIR
TWISTED
PAIR
TWISTED TWISTED
PAIR PAIR
TWISTED
PAIR
TWISTED TWISTED
PAIR PAIR
TWISTED
PAIR
TWISTED
8W - 47 - 8 8W-47 AUDIO SYSTEM
STANDARD
ZG-RHD
J978W-3 ZGR04707
11
C1 2
6 9 8 12 5 3
FUSED
B (+)
LEFT
FRONT
(+) (-)
FRONT
LEFT
(+)
REAR
LEFT
(-)
REAR
LEFT
(+)
FRONT
RIGHT
(-)
FRONT
RIGHT
GROUND
RIGHT
REAR
(+)
10 7
(-)
REAR
RIGHT
GROUND
16
RIGHT
REAR
(-) (+)
REAR
RIGHT RIGHT
FRONT
(-)
RIGHT
FRONT
(+)
LEFT
REAR
(-)
LEFT
REAR
(+)
LEFT
FRONT
(-) (+)
FRONT
LEFT
4 C3 C1 2 C3 2 C3 6 C3 5 C1 3 C3 3 C3 7
POWER
AMPLIFIER
RADIO
X53
16
DG
X53
20
DG
X55
16
BR/RD
X55
20
BR/RD
X51
16
BR/YL
X51
20
BR/YL
X57
16
BR/LB
X57
20
BR/LB
X54
16
VT
X54
20
VT/YL
X56
16
DB
X56
20
DB
X52
16
DB/WT
X52
20
DB/WT
X58
16
DB/OR
X58
20
DB/WT
7
C305
14 13
8
8
13
7
14
11
10
10
11
5
2
6
1
Z5
16
BK/LB
Z5
16
BK/LB
Z5
14
BK/LB
G303
S309
B (+)
FUSED
17 C1
ANTENNA
7
FUSE
20A
BATT A250
BLOCK
JUNCTION
F75
16
VT
F75
16
VT
F75
14
VT
S318
ANTENNA
C1 C1 C1 C1 C1 C1 C1 C1 C1 C1
8
C13
(8W-10-10)
(8W-12-2)
(8W-12-8)
(8W-15-13)
ZG-RHD 8W-47 AUDIO SYSTEM
LTD
8W - 47 - 9
ZGR04708 J978W-3
C2
6
C1 2
14
C2
5
C2
13
C2
4
C1
10
C1
10
C2
FUSED
B (+)
LEFT
FRONT
(+) (-)
FRONT
LEFT
(+)
REAR
LEFT
(-)
REAR
LEFT
(+)
FRONT
RIGHT
(-)
FRONT
RIGHT
GROUND
RIGHT
REAR
(+)
C1
6 5
C1
(-)
REAR
RIGHT
GROUND
C2
11
RIGHT
REAR
(-) (+)
REAR
RIGHT RIGHT
FRONT
(-)
RIGHT
FRONT
(+)
LEFT
REAR
(-)
LEFT
REAR
(+)
LEFT
FRONT
(-) (+)
FRONT
LEFT
4 C3 C1 2 C3 2 C3 6 C3 5 C1 3 C3 3 C3 7
POWER
AMPLIFIER
RADIO
X53
16
DG
X53
20
DG
X55
16
BR/RD
X55
20
BR/RD
X51
16
BR/YL
X51
20
BR/YL
X57
16
BR/LB
X57
20
BR/LB
X54
16
VT
X54
20
VT/YL
X56
16
DB
X56
20
DB
X52
16
DB/WT
X52
20
DB/WT
X58
16
DB/OR
X58
20
DB/OR
7
C305
14 13
8
8
13
7
14
11
10
10
11
5
2
6
1
Z5
16
BK/LB
Z5
16
BK/LB
Z5
14
BK/LB
G303
S309
B (+)
FUSED
17 C1
ANTENNA
7
FUSE
20A
BATT A250
BLOCK
JUNCTION
F75
16
VT
F75
16
VT
F75
14
VT
S318
ANTENNA
8
C13
(8W-10-10)
(8W-12-2)
(8W-12-8)
(8W-15-13)
8W - 47 - 10 8W-47 AUDIO SYSTEM
PREMIUM
ZG-RHD
J978W-3 ZGR04709
3 C2 C2 9
AMPLIFIER
POWER
B
A
A
B
X58
20
DB/OR
X91
16
WT/BK
X92
16
TN/BK
X52
20
DB/RD
SPEAKER
DOOR
REAR
LEFT RIGHT
REAR
DOOR
SPEAKER
C343 C345
C2
10
POWER
AMPLIFIER
A C343
X93
16
WT/RD
X52
20
DB/WT
8
C2
X94
16
TN/RD
A
C345
X58
20
DB/OR
AMPLIFIED
LEFT
REAR
(+) (+)
REAR
RIGHT
AMPLIFIED
B
B
SPEAKER
REAR
C
D
A
B
X95
16
BR/YL
X98
16
DB/OR
X97
16
BR/LB
X98
16
DB/WT
4 C2 C2 6
C2
5 7
C2
AMPLIFIED
REAR
(+) (+)
REAR
AMPLIFIED
AMPLIFIED
REAR
(-) (-)
REAR
AMPLIFIED AMPLIFIED
RIGHT
REAR
(-)
AMPLIFIED
LEFT
REAR
(-)
B
A
ZG-RHD 8W-47 AUDIO SYSTEM
LTD
8W - 47 - 11
ZGR04710 J978W-3
C1
19
1
C2
C1 20 2 C2
RADIO
BODY
CONTROL
MODULE
CCD
BUS
(+)
(+)
BUS
CCD
CCD
BUS
(-) (-)
BUS
CCD
RADIO
CONTROL
MUX
C2
3
C3 C30
C28
C3
CCD
BUS
(+)
(-)
BUS
CCD
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D1
18
VT/BR
D1
18
VT/BR
S203
S204
C235
709
20
RD/BK
3
CLOCKSPRING
4
Z2
20
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
Z2
18
BK/OR
G304
S302
S205
C307
CLOCKSPRING
G20
G10
G11
G19
8
MODULE
CONTROL
POWERTRAIN
MODULE
CONTROL
BODY
C235
D1
18
VT/BR
RADIO
LEFT
RADIO
REMOTE
SWITCH
RIGHT
RADIO
REMOTE
SWITCH
VEHICLE
SPEED
CONTROL/
SWITCH
HORN
8 7
6
9 10
7 SEEK DN
9 VOL DN
8 SEEK UP
6 PRESET
10 VOL UP
(8W-45-2)
(8W-45-7)
(8W-30-18)
(8W-30-19)
(8W-15-18)
(8W-15-18)
(8W-45-2)
(8W-15-18)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-45-2)
(8W-45-7)
8W - 47 - 12 8W-47 AUDIO SYSTEM ZG-RHD
J978W-3 ZGR04711
C2 4
LEFT
REAR
HIGH
(+) (-)
HIGH
REAR
LEFT
7 C2 C2 5
RIGHT
REAR
HIGH
(-) (+)
HIGH
REAR
RIGHT
6 C2
POWER
AMPLIFIER
(LTD+)
B
C
D
A
REAR
SPEAKER
X95
16
BR/YL
X97
16
BR/LB
X96
16
DB/OR
X98
16
DB/WT
ZG-RHD 8W-47 AUDIO SYSTEM 8W - 47 - 13
ZGR04712 J978W-3
8W-47 AUDIO SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION AND OPERATION
AMPLIFIER AND SPEAKERSPREMIUM . . . . . 14
LIMITED PLUS SYSTEM . . . . . . . . . . . . . . . . . . 15
POWER ANTENNAEXPORT ONLY . . . . . . . . . 15
RADIO ILLUMINATION . . . . . . . . . . . . . . . . . . . 14
RADIO MEMORY . . . . . . . . . . . . . . . . . . . . . . . 14
RADIO REMOTE SWITCHES . . . . . . . . . . . . . . 15
SPEAKERSSTANDARD SYSTEM . . . . . . . . . . 14
GENERAL INFORMATION
INTRODUCTION
There are three audi o systems offered on thi s vehi -
cl e. The standard system uses four speakers. The
premi um system i ncl udes 120 watt ampl i fi er, I nfi ni ty
coaxi al ful l -range speakers mounted i n each rear
door, I nfi ni ty mi d-range speakers mounted i n each
front door, and I nfi ni ty tweeters mounted at each
outboard end of the i nstrument panel cover. The Li m-
i ted Pl us system i ncl udes 180 watt ampl i fi er, I nfi ni ty
woofers mounted i n each rear door, I nfi ni ty mi d-
range speakers mounted i n each front door, I nfi ni ty
tweeters mounted at each outboard end of the i nstru-
ment panel cover, and a sound bar i ncl udi ng two
I nfi ni ty woofers and two I nfi ni ty tweeters.
Al l systems are powered by ci rcui t X12 from fuse 1
i n the juncti on bl ock. When the i gni ti on swi tch i s i n
the ACCESSORY or RUN posi ti on, i t connects ci rcui t
A1 from fuse 8 i n the Power Di stri buti on Center
(PDC) to ci rcui t A31. Ci rcui t A31 powers ci rcui t X12
through juncti on bl ock fuse 1.
Ci rcui t Z5 provi des ground for al l radi os.
Al l radi os connect to the CCD bus on ci rcui ts D1
and D2.
DESCRIPTION AND OPERATION
RADIO MEMORY
On the standard and opti onal radi os, ci rcui t F60
from fuse 20 i n the juncti on bl ock powers the radi o
memory. Ci rcui t A7 from fuse 15 i n the Power Di stri -
buti on Center (PDC) powers juncti on bl ock fuse 20
and ci rcui t F60.
RADIO ILLUMINATION
When the parki ng l amps or the headl amps are ON,
ci rcui ts E2 and L90 are used to power the radi o i l l u-
mi nati on l amps. Ci rcui t E2 i s used for the di mmabl e
l amps. Ci rcui t L90 i s the parki ng l amps feed.
SPEAKERS STANDARD SYSTEM
The standard system uses four speakers. Ci rcui t
X53 feeds the speaker i n the l eft front door. Ci rcui t
X55 i s the return from the speaker to the radi o.
Ci rcui t X54 feeds the ri ght front door speaker. Ci r-
cui t X56 i s the return from the speaker to the radi o.
From the radi o, ci rcui t X51 connects to ci rcui t X52
at the jumper harness for the l eft rear door speaker.
Ci rcui t X51 and X52 feed the speaker. Ci rcui t X58
from the speaker jumper harness connects to ci rcui t
X57. Ci rcui t X57 i s the return from the speaker to
the radi o.
Ci rcui t X52 feeds the ri ght rear door speaker. Ci r-
cui t X58 i s the return from the speaker to the radi o.
Ci rcui ts X52 and X58 conti nue through the jumper
harness to the ri ght rear door speaker.
AMPLIFIER AND SPEAKERS PREMIUM
A power ampl i fi er i s used on premi um systems
onl y. The ampl i fi er i s connected between the radi o
and the speakers.
Ci rcui t A250 from fuse 11 i n the Power Di stri bu-
ti on Center (PDC) powers ci rcui t F75 through fuse 7
i n the juncti on bl ock. Ci rcui t F75 feeds the radi o
ampl i fi er. Ci rcui t Z5 provi des ground for the ampl i -
fi er. Ci rcui t X60 from the radi o suppl i es power to the
ampl i fi er.
From the radi o, ci rcui ts X54 and X56 for the ri ght
front speaker and the speaker i n the ri ght si de of the
i nstrument panel , connect to the power ampl i fi er.
Ci rcui t X54 i s the feed from the radi o to the ampl i -
fi er. Ci rcui t X82 i s the feed from the ampl i fi er to the
ri ght i nstrument panel speaker and ri ght front door
speaker. Ci rcui t X80 i s the return from the speakers
to the ampl i fi er and ci rcui t X56 i s the return from
the ampl i fi er to the radi o. Ci rcui ts X80 and X82 from
the ampl i fi er connect to ci rcui ts X56 and X54 at the
jumper harness for the ri ght front door speaker.
For the l eft front door speaker and the speaker i n
the l eft si de of the i nstrument panel , ci rcui ts X53
and X55 from the radi o connect to the power ampl i -
fi er. Ci rcui t X53 i s the feed from the radi o to the
ampl i fi er. Ci rcui t X87 i s the feed from the ampl i fi er
8W - 47 - 14 8W - 47 AUDIO SYSTEM ZG
to the l eft i nstrument panel speaker and l eft front
door speaker. Ci rcui t X85 i s the return from speakers
to the ampl i fi er and ci rcui t X55 i s the return from
the ampl i fi er to the radi o. Ci rcui ts X87 and X85 from
the ampl i fi er connect to ci rcui ts X55 and X53 at the
jumper harness for the l eft front door speaker.
Ci rcui t X51, the feed for the l eft rear door speaker
and ci rcui t X57, the return for the speaker, connect
from the radi o to the power ampl i fi er. At the jumper
harness for the l eft rear door speaker, ci rcui t X93
from the ampl i fi er connects to ci rcui t X52 and ci rcui t
X91 connects to ci rcui t X58. Ci rcui ts X93 and X52
feed the speaker. The speaker return i s on ci rcui t
X58 and ci rcui t X91.
Ci rcui t X52, the feed for the ri ght rear door
speaker and ci rcui t X58, the return for the speaker,
connect from the radi o to the power ampl i fi er. At the
jumper harness for the ri ght rear door speaker, ci r-
cui t X94 from the ampl i fi er connects to ci rcui t X52
and ci rcui t X92 connects to ci rcui t X58. Ci rcui ts X94
and X52 feed the speaker. The speaker return i s on
ci rcui ts X58 and X92.
RADIO REMOTE SWITCHES
Premi um radi os have remote vol ume, seek, and
preset swi tches on the steeri ng wheel . The remote
swi tches connect to the Body Control Modul e (BCM)
on ci rcui t 709 and ground on ci rcui t Z2. Each swi tch
i s wi red i n paral l el . A resi stor i n seri es between each
swi tch and ground ci rcui t Z2 determi nes the si gnal
sensed by the BCM on ci rcui t 709.
After sensi ng a request from the radi o remote
swi tches, the BCM si gnal s the radi o over the CCD
bus to make the requested sel ecti on.
LIMITED PLUS SYSTEM
The ci rcui ts for the Li mi ted Pl us system are the
same as the Premi um System except for the sound
bar, mounted on the i nsi de roof headl i ner just for-
ward of the l i ftgate.
For the speakers housed i n the sound bar, ci rcui t
X95 from the ampl i fi er i s the feed for the l eft speak-
ers. Ci rcui t X97 i s the return to the ampl i fi er for the
l eft speakers. Ci rcui t X98 from the ampl i fi er i s the
feed for the ri ght speakers. Ci rcui t X96 i s the return
to the ampl i fi er for the ri ght speakers.
POWER ANTENNA EXPORT ONLY
The power antenna i s onl y used on vehi cl es bui l t
for export markets.
The power antenna rel ay suppl i es vol tage to the
power antenna motor. The rel ay suppl i es vol tage to
the antenna motor to ei ther rai se or l ower the
antenna.
Ci rcui t A7 from fuse 15 i n the Power Di stri buti on
Center (PDC) feeds the rel ay swi tch through fuse 13
i n the juncti on bl ock.
When the radi o i s OFF, the swi tch i n the power
antenna rel ay i s i n the DOWN posi ti on. I n DOWN
posi ti on, the rel ay swi tch powers ci rcui t X14. Ci rcui t
X14 suppl i es vol tage to power antenna motor to
l ower the antenna. The ground path i s from the
motor to the rel ay on ci rcui t X16, through the swi tch
i n the rel ay to ground on ci rcui t Z1.
Ci rcui t Z1 al so provi des ground for the coi l si de of
the power antenna rel ay. When the radi o i s turned
ON, ci rcui t X60 from the radi o suppl i es power to the
coi l si de of antenna rel ay and the rel ay swi tches to
the UP posi ti on. I n the UP posi ti on, the swi tch pow-
ers ci rcui t X16. Ci rcui t X16 suppl i es vol tage to power
the antenna motor to rai se the antenna. The ground
path i s from the motor to the rel ay on ci rcui t X17,
through the swi tch i n the rel ay to ground on ci rcui t
Z1.
ZG 8W - 47 AUDIO SYSTEM 8W - 47 - 15
DESCRIPTION AND OPERATION (Continued)
8W-48 REAR WINDOW DEFOGGER
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Page
Body Control Modul e . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-48-2
Component Page
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-48-2
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
ZG 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1
Z1
12
BK
Z1
12
BK
Z1
12
BK
Z1
12
BK
G300
S316
3
C325
S328
85 87
30 86
C9
1
REAR
WINDOW
DEFOGGER
RELAY
10A
FUSE
10
8
C10
C14
20
WT/RD
C16
20
LB/YL
9
SWITCH
DEFOGGER
WINDOW
REAR
C2 14 8 C1
C80
20
DB/YL
REAR
WINDOW
DEFOGGER
RELAY
CONTROL SENSE
SWITCH
DEFOGGER
WINDOW
REAR
BODY
CONTROL
MODULE
2
G304
Z1
14
BK
Z1
14
BK
Z1
16
BK
Z1
20
BK
S202
S216
2 C301
C15
12
BK/WT
C15
12
BK/WT
1 C301
2
C322
LIFTGLASS OTHERS
C15
12
BK/LB
C15
12
BK/LB
C15
12
BK
S332
DEFOGGER
WINDOW
REAR
JUNCTION
BLOCK
3 C6
BATT A900
10
2
SWITCH POD)
(PART OF
3
(8W-10-4)
(8W-12-2)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-45-3)
(8W-45-9)
(8W-12-9)
(8W-15-10)
(8W-45-11)
(8W-15-11)
(8W-15-11)
8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER ZG-RHD
J978W-3 ZGR04801
8W-48 REAR WINDOW DEFOGGER
DESCRIPTION AND OPERATION
REAR WINDOW DEFOGGER
The Body Control Modul e (BCM) operates the rear
wi ndow defogger system through a rel ay l ocated i n
the juncti on bl ock. When the operator presses the
rear wi ndow defogger swi tch, the swi tch connects ci r-
cui t C80 from the BCM to ground ci rcui t Z1. I n
response, the BCM grounds the coi l si de of the rear
wi ndow defogger rel ay on ci rcui t C14.
When the BCM grounds the rear wi ndow defogger
rel ay coi l , the contacts cl ose and connect ci rcui t A900
from fuse 3 i n the Power Di stri buti on Center (PDC)
to ci rcui t C15. Ci rcui t C15 suppl i es power to the rear
wi ndow defogger gri d. Ci rcui t A900 al so powers the
coi l si de of the rel ay. Ci rcui t Z1 grounds the rear
wi ndow defogger gri d.
I nternal to the juncti on bl ock, ci rcui t C15 spl i ces to
feed ci rcui t C16 through fuse 10. Ci rcui t C16 feeds
the Li ght Emi tti ng Di ode (LED) i n the rear wi ndow
defogger swi tch.
ZG 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 3
8W-49 OVERHEAD CONSOLE
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Page
Body Control Modul e . . . . . . . . . . . . . . . . . . 8W-49-2
Courtesy Lamp Rel ay . . . . . . . . . . . . . . . . . 8W-49-3
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3
Overhead Consol e . . . . . . . . . . . . . . . . . . 8W-49-2, 3
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-49-2
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
Component Page
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
ZG 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1
3 5
D1
18
VT/BR
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
C1
19
C28
C3
S203 S204
D2
18
WT/BK
D2
18
WT/BK
D1
18
VT/BR
D1
18
VT/BR
19 20
C235
10
11
D1
18
VT/BR
D2
18
WT/BK
1 2 C231
CONSOLE
OVERHEAD
C30
C3
20
C1
MODULE
CONTROL
BODY
6
FUSE
15A
3
RUN A22
BLOCK
JUNCTION
C15
1
IGN.
FUSED
(RUN)
F83
20
YL/DG
F83
20
YL/DG
S323
CCD
BUS
(+) (-)
BUS
CCD
(+)
BUS
CCD CCD
BUS
(-)
CCD
BUS
(+) (-)
BUS
CCD
MODULE
CONTROL
POWERTRAIN
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
PAIR
TWISTED
PAIR
TWISTED
(8W-10-8)
(8W-30-18)
(8W-30-19)
(8W-12-7)
(8W-12-2)
(8W-12-6)
(8W-45-2)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
8W - 49 - 2 8W-49 OVERHEAD CONSOLE ZG-RHD
J978W-3 ZGR04901
16
FUSE
10A
9
BATT A7
BLOCK
JUNCTION
C15
M1
20
PK
M1
20
PK
S321
4 2
6
OVERHEAD
CONSOLE
C5
4
C15 2
Z1
20
BK
Z1
16
BK
S322
Z1
18
BK
S220
Z1
18
BK
M2
20
YL
M2
20
YL
M2
20
YL
S334
Z1
16
BK
Z1
14
BK
Z1
14
BK
G304
S202
S216
2 C301
OVERHEAD
CONSOLE OTHERS
30
87
(IN JB)
RELAY
LAMP
COURTESY JUNCTION
BLOCK
16
BK
Z1
(8W-12-2)
(8W-10-12)
(8W-44-8)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-12-21)
(8W-15-17)
(8W-12-21)
(8W-15-16)
(8W-12-13)
(8W-12-2)
(8W-12-12)
ZG-RHD 8W-49 OVERHEAD CONSOLE 8W - 49 - 3
ZGR04902 J978W-3
8W-49 OVERHEAD CONSOLE
DESCRIPTION AND OPERATION
OVERHEAD CONSOLE
When the i gni ti on swi tch i s i n the RUN posi ti on, i t
connects ci rcui t A1 from fuse 8 i n the Power Di stri -
buti on Center (PDC) to ci rcui t A22. Ci rcui t A22 pow-
ers ci rcui t F83 through fuse 6 i n the juncti on bl ock.
Ci rcui t F83 suppl i es power to the overhead consol e.
The Body Control Modul e (BCM) broadcasts the
park l amp si gnal and i nstrument panel i l l umi nati on
l amp i ntensi ty si gnal on the CCD bus. The overhead
consol e recei ves the si gnal s over the CCD bus and
cal cul ates di spl ay i l l umi nati on i ntensi ty.
The overhead consol e recei ves the fuel percentage
and di stance i nformati on on the CCD bus from the
Powertrai n Control Modul e (PCM).
The overhead consol e contai ns a US/Metri c swi tch.
The swi tch sel ects whi ch uni ts to show on the di s-
pl ay. The overhead consol e broadcasts the US/Metri c
sel ecti on on the CCD bus.
OVERHEAD CONSOLE LAMPS
Ci rcui t A7 from fuse 15 i n the Power Di stri buti on
Center (PDC) powers ci rcui t M1 through fuse 16 i n
the juncti on bl ock. Ci rcui t M1 feeds the overhead
consol e l amps.
Each overhead consol e l amp has a swi tch that con-
nects the l amps to ground on ci rcui t Z1. The l amps
are al so grounded when the Body Control Modul e
(BCM) energi zes the courtesy l amp rel ay to connect
ci rcui t M2 to ground on ci rcui t Z1.
8W - 49 - 4 8W - 49 OVERHEAD CONSOLE ZG
8W-50 FRONT LIGHTING
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Component Page
Automati c Headl amp Li ght Sensor/Vtss Led . 8W-50-5
Automati c Headl amp Rel ay . . . . . . . . . . . 8W-50-2, 5
Body Control Modul e . . . . . . 8W-50-2, 3, 4, 5, 6, 7, 8
Brake Warni ng Swi tch . . . . . . . . . . . . . . . . 8W-50-4
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Dayti me Runni ng Lamp Modul e . . . . . . . 8W-50-3, 4
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-50-7
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 4
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-7, 8
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 6
G106 . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 6, 9, 10
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
G304 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5, 7, 11
Headl amp Di mmer Swi tch . . . . . . . . . . . 8W-50-2, 5
Headl amp Level i ng Swi tch . . . . . . . . . . . . 8W-50-11
Headl amp Swi tch . . . . . . . . . . . . . . . . 8W-50-2, 5, 7
I nstrument Cl uster . . . . . . . . . . . . . . . . 8W-50-9, 10
Juncti on Bl ock . . . . . . . . . . . . 8W-50-2, 4, 6, 7, 8, 10
Lamp Outage Modul e . . . . . . . . . . . . . . . . . 8W-50-8
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Left Front Park Lamp . . . . . . . . . . . . . . . . . 8W-50-9
Left Front Turn Si gnal Lamp . . . . . . . . . . . 8W-50-9
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Left Headl amp Level i ng Motor . . . . . . . . . 8W-50-11
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . 8W-50-4
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8W-50-7, 8
Power Di stri buti on Center . . . . . . . . . 8W-50-2, 4, 6
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Component Page
Ri ght Front Park Lamp . . . . . . . . . . . . . . . 8W-50-10
Ri ght Front Turn Si gnal Lamp . . . . . . . . . 8W-50-10
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Ri ght Headl amp Level i ng Motor . . . . . . . . 8W-50-11
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8
S104 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 6, 10
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 6, 9
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9
S149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9
S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-10
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-10
S202 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5, 7, 11
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 11
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
S408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-10
S409 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9
Turn Si gnal /Hazard Warni ng Swi tch . . . 8W-50-9, 10
Vehi cl e I nformati on Center . . . . . . . . . . . . . 8W-50-8
ZG 8W - 50 FRONT LIGHTING 8W - 50 - 1
15
FUSE
40A
28
BATT A0
21 19
26
30A
FUSE
13
15A
FUSE
19
C2 2
2 C7
A7
12
YL/RD
8 C1
30 86
85 87
A6
14
RD/LB
C5 8 12 C10
18
19 21
20
2
3
HEADLAMP
DIMMER
SWITCH
(PART OF
MULTI-FUNCTION
11
SWITCH
HEADLAMP
L11
16
LG/BK
F34
16
TN/BK
F34
16
TN/BK
L3
16
RD/OR
TO
C234
C1 9
BODY
CONTROL
MODULE
DIMMER
SWITCH
LOW
BEAM
OUTPUT
CONTROL
RELAY
HEADLAMP
AUTOMATIC
12 C2
L4
16
VT/OR
C234
TO
L4
16
VT/OR
714
20
BK/OR
B
(8W-50-3)
A
(8W-50-3)
CENTER
DISTRIBUTION
POWER
JUNCTION
BLOCK
1 2 1
3
SWITCH)
3 HIGH
2 FLASH TO PASS
1 LOW
AUTOMATIC
HEADLAMP
RELAY
(8W-12-2)
(8W-10-3)
(8W-10-3)
(8W-45-5)
(8W-12-16)
(8W-10-11) (8W-10-12)
8W - 50 - 2 8W-50 FRONT LIGHTING ZG-RHD
J978W-3 ZGR05001
FROM
SWITCH
DIMMER
HEADLAMP
FROM
SWITCH
DIMMER
HEADLAMP
S108 S107
L4
16
VT/OR
L4
16
VT/OR
F3 C234 C234 F2
L3
16
RD/OR
L3
16
RD/OR
L4
16
VT/OR
L3
16
RD/OR
3 2
1
1
2 3
L3
16
RD/OR
L4
16
VT/OR
Z1
16
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
G106
S104
S109
LEFT
HEADLAMP
RIGHT
HEADLAMP
OUTPUT
BEAM
HIGH
SWITCH
DIMMER
MODULE
CONTROL
BODY
24
B
(8W-50-2)
A
(8W-50-2)
F12 C234
L3
16
RD/OR
C1
BK
16
Z1
16
BK
Z1
G109
GAS DIESEL
(8W-15-4)
(8W-15-5)
(8W-45-5)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-15-7)
(8W-15-6)
(8W-15-7)
ZG-RHD 8W-50 FRONT LIGHTING 8W - 50 - 3
ZGR05002 J978W-3
1
BRAKE
WARNING
SWITCH
2 C304
S303
G9
20
GY/BK
G9
18
GY/BK
SWITCH
BRAKE
PARK
G9
20
GY/BK
MODULE
CONTROL
BODY
C3 2
BRAKE
SWITCH
SENSE
(8W-45-9)
(8W-40-6)
8W - 50 - 4 8W-50 FRONT LIGHTING ZG-RHD
J978W-3 ZGR05003
25A
BREAKER
CIRCUIT
13 11
BATT A6
G304
Z1
14
BK
Z1
16
BK
2 C301
C1 7
L24
20
LB/RD
19
HEADLAMP
DIMMER
SWITCH
F34
16
TN/BK
87
(IN JB)
RELAY
HEADLAMP
AUTOMATIC
F34
16
TN/BK
BODY
CONTROL
MODULE
AUTOMATIC
HEADLAMP
SWITCH
SENSE DRIVER
SENSOR
LIGHT
ULTRA
2 C2 C2 9
ULTRA
LIGHT
SENSOR
SIGNAL
3 4
LED
VTSS
SENSOR/
LIGHT
HEADLAMP
AUTOMATIC
L109
20
WT
L110
20
OR/BK
2
Z1
14
BK
S202
3 LOW
2 PARK
0 OFF
1 AUTO
SWITCH
HEADLAMP
3
2 0
1 3
2 0
1
1
S209
OR
20
E2
OR
20
E2
C2
PANEL
LAMPS
DRIVER
16
SWITCH)
MULTI-FUNCTION
(PART OF
(8W-44-11) (8W-15-18)
(8W-10-11)
(8W-45-5)
(8W-15-18)
ZG-RHD 8W-50 FRONT LIGHTING 8W - 50 - 5
ZGR05004 J978W-3
19
FUSE
20A
A18
A17
BATT A0
F62
18
RD
C7
8
C1 5
85 87
30 86
4
C1
1
C10
C2 22
FOG
LAMP
RELAY
CONTROL
BODY
CONTROL
MODULE
L95
20
DG/YL
E
(8W-50-7)
TO
SWITCH
LAMP
FOG
L39
20
LB
L39
18
LB
1
2
1
2
L39
18
LB
L39
18
LB
S105
Z1
18
BK
Z1
18
BK
Z1
16
BK
Z1
10
BK
S109
S104
G106
RELAY
LAMP
FOG
LAMP
FOG
LEFT
RIGHT
FOG
LAMP
CENTER
DISTRIBUTION
POWER
JUNCTION
BLOCK
GAS
DIESEL
Z1
14
BK
(8W-12-2)
(8W-10-3)
(8W-10-3)
(8W-15-6)
(8W-15-7)
(8W-52-8)
(8W-52-8)
(8W-12-24)
(8W-45-5)
(8W-10-13)
8W - 50 - 6 8W-50 FRONT LIGHTING ZG-RHD
J978W-3 ZGR05005
17
FUSE
15A
A18
A17
BATT A6
E
(8W-50-6)
FROM
RELAY
LAMP
FOG
L39
20
LB
85 87
30 86
10 10
C10 C8
PARK
LAMP
RELAY
C9
11
SWITCH
LAMP
FOG
15
3 LOW
2 PARK
0 OFF
1 AUTO
SWITCH
HEADLAMP
6 5
15 C1 C2 21
L79
20
TN
L90
20
DB/RD
L35
20
BR/WT
Z1
16
BK
Z1
14
BK
Z1
14
BK
S202
C301
G304
PARK
LAMP
RELAY
CONTROL SENSE
SWITCH
LAMP
FOG
MODULE
CONTROL
BODY
JUNCTION
BLOCK
366
16
PK/OR
3
2 0
1
4 16
PANEL
LAMP
DIMMER
20 C2
BK/WT
707
20
8
SWITCH
SENSE
2
(8W-10-11)
(8W-12-2)
(8W-45-4)
(8W-45-6)
(8W-15-18)
(8W-15-18)
(8W-12-14)
ZG-RHD 8W-50 FRONT LIGHTING 8W - 50 - 7
ZGR05006 J978W-3
BATT A6
87
86
C10
10 11
C10 C3
9
15A
FUSE
17
PARK
LAMP
RELAY
CONTROL
RELAY
LAMP
PARK
21 C2
L79
20
TN
C1 17
PARK
LAMP
RELAY
OUTPUT
L90
20
DB/RD
BODY
CONTROL
MODULE
L90
18
DB/RD
L90
18
DB/RD
L90
18
DB/RD
TO
C102
TO
C150
S103
C
(8W-50-9)
D
(8W-50-10)
JUNCTION
BLOCK
30
85
4
C8
DB/RD
20
L90
4 C1
RADIO
L90
20
DB/RD
11
5
C8
CENTER
VEHICLE
INFORMATION
PARK
LAMP
RELAY
OUTPUT
3
MODULE
LAMP
OUTAGE
4
OUTPUT
RELAY
PARK
LAMP LAMP
PARK
RELAY
OUTPUT
5
DB/RD
18
L90
4
C8
(OPTIONAL)
DB/RD
L90
18
L90
DB/RD
18
C1 C1 C1
(8W-51-2)
(8W-46-6)
(8W-47-2)
(8W-12-2)
(8W-10-11)
(8W-45-4)
(8W-12-14)
8W - 50 - 8 8W-50 FRONT LIGHTING ZG-RHD
J978W-3 ZGR05007
6
CLUSTER
INSTRUMENT
L65
18
LG/DB
L65
18
LG/DB
L65
18
LG/DB
C
(8W-50-8)
1 2
C102
L90
18
DB/RD
LAMP
SIGNAL
TURN
FRONT
LEFT
B
A
L90
18
DB/RD
L90
18
DB/RD
F10 C234
S409
S147
S103
FROM
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
16
BK
L64
18
TN/DB
G106
3 C102
S109
S149
16
G
A
SWITCH
WARNING
HAZARD
SIGNAL/
TURN
LEFT
TURN
SIGNAL
FEED
LAMP
PARK
FRONT
SIGNAL
INDICATOR
LEFT
TURN
LEFT
L65
LG/DB
18
(8W-52-2)
(8W-15-4)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-15-7)
(8W-52-8)
(8W-15-5)
(8W-40-4)
ZG-RHD 8W-50 FRONT LIGHTING 8W - 50 - 9
ZGR05008 J978W-3
CLUSTER
INSTRUMENT
BLOCK
JUNCTION
L64
18
TN
L64
18
TN/DB
L64
18
TN/DB
D
(8W-50-8)
2
1 C150
L90
18
DB/RD
L64
18
TN/DB
LAMP
SIGNAL
TURN
FRONT
RIGHT
B
A
G
A
L90
18
DB/RD
L90
18
DB/RD
S150
S103
FROM
1 C4 5 C4
11
C1
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
14
BK
G106
3 C150
S104
7
11
S152
FEED
SIGNAL
TURN
RIGHT
TURN
SIGNAL/
HAZARD
WARNING
SWITCH
FRONT
PARK
LAMP
INDICATOR
SIGNAL
RIGHT
TURN
RIGHT
C150
S408
TN/DB
18
L64
(8W-12-17)
(8W-52-2)
(8W-15-6)
(8W-15-7)
(8W-15-6)
(8W-15-7)
(8W-15-6)
(8W-15-7)
(8W-52-8)
(8W-12-2)
(8W-40-4)
8W - 50 - 10 8W-50 FRONT LIGHTING ZG-RHD
J978W-3 ZGR05009
6
MOTOR
LEVELING
HEADLAMP
LEFT RIGHT
HEADLAMP
LEVELING
MOTOR
5 4 3
L101
20
RD
L106
20
YL
L105
20
PK
L102
20
WT LG
20
L104
LB
20
L103
1 2 5 6
L106
20
YL
L101
20
RD PK
20
L105
WT
20
L102
LB
20
L103
LG
20
L104
4 3 2 1
S114
S113
S112
S115
S110
S111
L101
20
RD
L101
20
RD
L106
20
YL
L106
20
YL
L105
20
PK
L105
20
PK
L102
20
WT
L102
20
WT
L103
20
LB
L103
20
LB
L104
20
LG
L104
20
LG
H5 C236 H4 H3 H6 H7 H2
6 2 8 7 3 4 5
SWITCH
LEVELING
HEADLAMP
F83
18
YL/DG
1
G304
Z1
20
BK
Z1
14
BK
Z1
14
BK
S202
2 C301
FROM
BLOCK
JUNCTION
GROUND
FUSED
IGN.
(RUN)
(8W-15-18)
(8W-12-2)
ZG-RHD 8W-50 FRONT LIGHTING 8W - 50 - 11
ZGR05010 J978W-3
8W-50 FRONT LIGHTING
INDEX
page page
DESCRIPTION AND OPERATION
AUTO HEADLAMPS . . . . . . . . . . . . . . . . . . . . . 12
FOG LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HEADLAMP LEVELING . . . . . . . . . . . . . . . . . . . 12
HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 12
PARKING LAMPS . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION AND OPERATION
INTRODUCTION
The vehi cl e i s equi pped wi th a Body Control Mod-
ul e (BCM). The BCM control s the auto headl amp fea-
ture through the auto headl amp rel ay.
The park l amps operate when the headl amp swi tch
i s i n the ON or PARK posi ti on. Al so, i f the vehi cl e i s
equi pped wi th the Vehi cl e Theft Securi ty System
(VTSS), the BCM powers the park l amps through the
park l amp rel ay i f i t senses unauthori zed vehi cl e
operati on.
Ci rcui t A6 from fuse 13 i n Power Di stri buti on Cen-
ter (PDC), powers the headl amp swi tch through the
ci rcui t breaker i n the swi tch.
PARKING LAMPS
Ci rcui t A6 from fuse 13 i n the Power Di stri buti on
Center (PDC) powers ci rcui t 366 through fuse 17 i n
the juncti on bl ock. When the headl amp swi tch i s i n
the PARK l amp posi ti on, i t connects ci rcui t 366 to
ci rcui t L90. Ci rcui t L90 powers the parki ng l amps,
si de marker l amps. Ci rcui t L90 al so connects to the
Body Control Modul e (BCM).
The BCM operates the park l amps when i t senses
unauthori zed entry to the vehi cl e whi l e the Vehi cl e
Theft Securi ty System i s armed. When i t sense unau-
thori zed entry, the BCM energi zes the park l amp
rel ay by provi di ng ground for the rel ay coi l on ci rcui t
L79. Ci rcui t 366 powers the rel ay coi l and contacts.
When the rel ay energi zes, i t connects ci rcui t 366 to
ci rcui t L90.
HEADLAMPS
When the headl amp swi tch i s i n the LOW posi ti on,
i t connects ci rcui t A6 from fuse 13 i n the Power Di s-
tri buti on Center (PDC) to ci rcui t F34. Ci rcui t F34
connects to the di mmer swi tch porti on of the mul ti -
functi on swi tch and feeds ci rcui t L4. Ci rcui t L4 pow-
ers the l ow beam of the headl amps.
When the operator sel ects hi gh beam operati on or
fl ash-to-pass wi th the turn si gnal stal k of the mul ti -
functi on swi tch, ci rcui t L11 from fuse 19 i n the junc-
ti on bl ock connects to ci rcui t L3. Ci rcui t L3 powers
headl amp hi gh beams. Ci rcui t L3 al so connects to the
Body Control Modul e (BCM).
I f the vehi cl e was bui l t for sal e i n the Country of
Canada, the Dayti me Runni ng Lamps (DRL) modul e
powers the headl amp hi gh beams on ci rcui t L3 when
the headl amp swi tch i s off and the i gni ti on swi tch i s
i n the RUN posi ti on.
HEADLAMP LEVELING
When the i gni ti on swi tch i s i n the RUN posi ti on, i t
connects ci rcui t A1 from fuse 8 i n the Power Di stri -
buti on Center (PDC) to ci rcui t A22. Ci rcui t A22 pow-
ers ci rcui t F83 through fuse 6 i n the juncti on bl ock.
Ci rcui t F83 feeds the headl amp l evel i ng swi tch. Ci r-
cui t Z1 grounds the swi tch.
AUTO HEADLAMPS
The Body Control Modul e (BCM) operates the Auto
Headl amp feature. The BCM moni tors outsi de l i ght
i ntensi ty through the auto headl amp l i ght sensor.
Ci rcui t L109 from the BCM provi des 5 vol ts to the
sensor. Ci rcui t L110 from the sensor sends the l i ght
i ntensi ty si gnal to the BCM.
I n the AUTO posi ti on, the headl amp swi tch pro-
vi des a si gnal to the BCM by connecti ng ci rcui t L24
to ground on ci rcui t Z1. I f outsi de l i ght i ntensi ty i s
l ow enough when the BCM senses the AUTO head-
l amp request, i t energi zes the auto headl amp rel ay
by groundi ng the rel ay coi l on ci rcui t 714. Ci rcui t A6
from fuse 13 i n the Power Di stri buti on Center (PDC)
powers the rel ay coi l and contacts.
When the rel ay energi zes, i t connects ci rcui t A6 to
ci rcui t F34. Ci rcui t F34 powers ci rcui t L4 through
the headl amp di mmer swi tch ci rcui try i n the mul ti -
functi on swi tch. Ci rcui t L4 powers the headl amps.
FOG LAMPS
The fog l amps onl y operate when the headl amp
hi gh beams are off and the park l amps are on. The
fog l amp swi tch contai ns a l i ght emi tti ng di ode
(LED) that i l l umi nates duri ng fog l amp operati on.
When the fog l amp swi tch cl oses, i t si gnal s the
Body Control Modul e (BCM) on ci rcui t L35. I f the
park l amps are on and the BCM does not sense head-
8W - 50 - 12 8W - 50 FRONT LIGHTING ZG
l amp hi gh beam operati on on ci rcui t L3, i t energi zes
the fog l amp rel ay. The BCM energi zes the rel ay by
groundi ng the rel ay coi l on ci rcui t L95. Ci rcui t F62
from fuse 19 i n the Power Di stri buti on Center (PDC)
powers the rel ay coi l and contacts.
When the fog l amp rel ay energi zes, i t connects ci r-
cui t F62 from fuse 19 i n the Power Di stri buti on Cen-
ter (PDC) to ci rcui t L39. Ci rcui t L39 powers the fog
l amps and the fog l amp swi tch LED. Ci rcui t Z1 pro-
vi des ground for the l amps and the LED.
ZG 8W - 50 FRONT LIGHTING 8W - 50 - 13
DESCRIPTION AND OPERATION (Continued)
8W-51 REAR LIGHTING
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Page
Aftermarket Trai l er Tow Connector . . . . . . . 8W-51-6
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-51-5
Body Control Modul e . . . . . . . . . . . . . . . . . . 8W-51-2
Center Hi gh Mounted Stop Lamp No. 1 . 8W-51-3, 5
Center Hi gh Mounted Stop Lamp No. 2 . 8W-51-3, 5
Center Hi gh Mounted Stop Lamp No. 3 . 8W-51-3, 5
Factory Trai l er Tow Connector . . . . . . . . . . 8W-51-6
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 7
G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4, 5, 6, 7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5, 6
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Headl amp Swi tch . . . . . . . . . . . . . . . . . . 8W-51-2, 7
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-51-2, 5, 6, 7
Lamp Outage Modul e . . . . . . . 8W-51-2, 3, 4, 5, 6, 7
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . 8W-51-6
Left Li cense Lamp . . . . . . . . . . . . . . . . . . . 8W-51-6
Left Rear Fog Lamp . . . . . . . . . . . . . . . . . . 8W-51-7
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . 8W-51-3, 4
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-51-2
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . 8W-51-5
Component Page
Rear Fog Lamp Rel ay A . . . . . . . . . . . . . . . 8W-51-7
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . 8W-51-6
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . . 8W-51-6
Ri ght Rear Fog Lamp . . . . . . . . . . . . . . . . . 8W-51-7
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . 8W-51-3, 4
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4, 5, 6
S316 . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4, 5, 6, 7
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
S411 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4, 6, 7
S412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3
S416 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3
S417 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4, 6, 7
S418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
S419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-51-2, 3
Trai l er Tow Stop Lamp Rel ay . . . . . . . . . . . 8W-51-3
Vehi cl e I nformati on Center . . . . . . . . . . . . . 8W-51-5
ZG 8W - 51 REAR LIGHTING 8W - 51 - 1
C10
3
JUNCTION
BLOCK
15A
FUSE
9
10A
FUSE
5
BATT A250 ST-RUN A21
7
C13
L16
18
RD/LG
5
6
STOP
LAMP
SWITCH
L50
18
WT/TN
PARK
LAMP
RELAY
85 87
30 86
17
FUSE
15A
C10
10 11
C10
11
C9
16
15
3
2 0
1
3 LO
2 PARK
0 OFF
1 AUTO
SWITCH
HEADLAMP
366
16
PK/OR
C2 21
L90
20
DB/RD
C8 10
JUNCTION
BLOCK
17 C1
L79
20
TN
L90
20
DB/RD
MODULE
CONTROL
BODY
PARK
LAMP
RELAY
CONTROL
PARK
RELAY
LAMP
OUTPUT
F87
18
WT/PK
10 3
C13
4
2 6 7 8
S312
L50
18
WT/TN
L50
18
WT/TN
L50
18
WT/TN
L50
18
WT/TN
LAMP
OUTAGE
MODULE
4 5
L90 18DB/RD L90 18DB/RD
PARK
LAMP
RELAY RELAY
LAMP
PARK PARK
LAMP
RELAY
L90
18
DB/RD
FUSED STOP
LAMP
SWITCH SWITCH
LAMP
STOP STOP
LAMP
SWITCH
INPUT
SWITCH
LAMP
STOP
BATT A6
IGN.
(ST-RUN)
INPUT INPUT INPUT INPUT INPUT INPUT
C1 C1 C1 C1 C1 C1 C1 C1
(8W-12-2)
(8W-12-7) (8W-12-5)
(8W-10-10) (8W-10-8)
(8W-33-2)
(8W-12-14)
(8W-50-2)
(8W-50-5)
(8W-50-7)
(8W-12-2)
(8W-45-4)
(8W-70-5)
(8W-10-11)
8W - 51 - 2 8W-51 REAR LIGHTING ZG-RHD
J978W-3 ZGR05101
STOP
LAMP
SWITCH
INPUT
SWITCH
LAMP
STOP STOP
LAMP
SWITCH SWITCH
LAMP
STOP
MODULE
OUTAGE
LAMP
WT/TN
18
L50
WT/TN
18
L50
WT/TN
18
L50
WT/TN
18
L50
S312
8 7 6 2
WT/TN
18
L50
SWITCH
LAMP
STOP
5
2 6 7 8 4 5
STOP
LAMP
SWITCH
OUPUT OUPUT
SWITCH
LAMP
STOP
OUPUT
SWITCH
LAMP
STOP
OUPUT
SWITCH
LAMP
STOP PARK
LAMP
RELAY
OUTPUT
PARK
LAMP
RELAY
OUTPUT
1
L50
18
WT/TN
L21
18
LB/WT
L22
18
LB
2 C328 2 C320
L22
18
LB
L22
18
LB
B B
1 C320
L74
18
PK/BK
A
LAMP
STOP
TAIL/
RIGHT
L73
18
PK/WT
L73
18
PK/WT
1 C328
L73
18
PK/WT
LEFT
TAIL/
STOP
LAMP
A
L87
18
DG/WT
1
C326
L87
18
DG/WT
A C359
L87
20
DG/WT
1
LAMP
STOP
MOUNTED
HIGH
CENTER
LAMP
STOP
TAIL/
RIGHT LEFT
TAIL/
STOP
LAMP
1 C372
L50
18
WT/TN
RELAY
LAMP
STOP
TOW
TRAILER
NO. 1
MOUNTED
LAMP
NO. 3
CENTER
HIGH
STOP
1
CENTER
MOUNTED
LAMP
NO. 2
1
STOP
HIGH
DG/WT
20
L87 L87
20
DG/WT
INPUT INPUT INPUT
8
C2 C2 C2 C2 C2 C2
C1 C1 C1 C1
(8W-51-5) (8W-51-5)
(8W-54-3)
(8W-51-4) (8W-51-4)
(8W-51-5)
(8W-51-4)
(8W-51-4)
(8W-33-2)
(8W-70-5)
ZG-RHD 8W-51 REAR LIGHTING 8W - 51 - 3
ZGR05102 J978W-3
PK/BK
18
L73
C328 1
PK/WT
18
L73
PK/WT
18
L73
PK/BK
18
L74
C320 1
LB
18
L22
LB/WT
18
L21
C320 2 C328 2
LB
18
L22
LB/WT
18
L21
OUTPUT
RELAY
LAMP
PARK
OUTPUT
RELAY
LAMP
PARK STOP
LAMP
SWITCH
OUPUT
STOP
LAMP
SWITCH
OUPUT
5 4 7 6
LAMP
OUTAGE
MODULE
LAMP
STOP
TAIL/
RIGHT
G
B A A B
G
LEFT
TAIL/
STOP
LAMP
S411
S417
Z1
18
BK
Z1
18
BK
Z1
18
BK
4 C328
Z1
18
BK
S314
Z1
12
BK
Z1
18
BK
4 C320
S316
Z1
18
BK
Z1
12
BK
G300
C2 C2 C2 C2
(8W-15-11)
(8W-15-11)
(8W-15-12)
(8W-15-11)
(8W-15-9)
8W - 51 - 4 8W-51 REAR LIGHTING ZG-RHD
J978W-3 ZGR05103
DG/WT
20
L87
C359 A
DG/WT
18
L87
C326
8
DG/WT
18
L87
GROUND
STOP
LAMP
SWITCH
OUPUT
8 9
LAMP
OUTAGE
MODULE
INDICATOR
OUT
LAMP
REAR
5
VEHICLE
INFORMATION
CENTER
G46
20
BK/LB
5 C307
G46
20
LB/BK
REAR
LAMP
OUT
INDICATOR
DRIVER
NO. 2
CENTER
HIGH
MOUNTED
STOP
LAMP
2
1 1
2
LAMP
STOP
MOUNTED
HIGH
CENTER
NO. 3
L87 20DG/WT
NO. 1
CENTER
HIGH
MOUNTED
STOP
LAMP
2
1
L87 20DG/WT
Z1 20BK Z1 20BK
B C359
Z1
18
BK
S316
Z1
12
BK
Z1
20
BK
7
C326
Z1
18
BK
G300
S314
Z1
18
BK
Z1
12
BK
G302
18
F83
C132 8
YL/DG
18
F83
YL/DG
18
F83
YL/DG
18
F83
S119
18
C235
12
YL/DG
18
F83
YL/DG
18
F83
S212
BLOCK
JUNCTION
1 C8
RUN A22
6
FUSE
15A
BR/LG
18
L10
PARK/
NEUTRAL
POSITION
SWITCH
1
YL/DG
TO
BLOCK
JUNCTION
A
(8W-51-6)
BR/LG
18
L10
C131 6
SPEED
PROPORTIONAL
STEERING OTHERS
2
C2
1
C2
C1
DIESEL GAS
YL/DG
2
F83
16
BACK-UP
LAMP
SWITCH
3 1
9
(8W-44-7)
(8W-12-6)
(8W-10-8)
(8W-12-2)
(8W-12-6)
(8W-70-8)
(8W-15-12)
(8W-15-12)
(8W-15-11)
(8W-15-11)
(8W-46-6)
ZG-RHD 8W-51 REAR LIGHTING 8W - 51 - 5
ZGR05104 J978W-3
3
LAMP
OUTAGE
MODULE
L90
18
DB/RD
11
C321
L90
20
DB/RD
B C364
L90
20
DB/RD
L90
20
DB/RD
L90
20
DB/RD
S419
S418
2
1
2
1
LAMP
LICENSE
LEFT RIGHT
LICENSE
LAMP
Z1
20
BK
Z1
20
BK
Z1
20
BK
A C364
S328
Z1
20
BK
Z1
12
BK
2
C325
S316
Z1
12
BK
Z1
12
BK
G300
L90
18
DB/RD
2 C372
2 C331
L90
18
DB/RD
3
L90
18
DB/RD
B
L90
18
DB/RD
PARK
LAMP
RELAY
OUTPUT
A
(8W-51-5)
FROM
C131
L10
18
BR/LG
C14
1
C3 2
JUNCTION
BLOCK
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
S311
3 C328 C320 3
L10
18
BR/LG
L10
18
BR/LG
G
A
G
A
LAMP
BACK-UP
LEFT RIGHT
BACK-UP
LAMP
Z1
18
BK
S417
Z1
18
BK
4 C320
Z1
18
BK
S411
Z1
18
BK
Z1
18
BK
4 C328
S314
Z1
18
BK
Z1
12
BK
G302
TOW
CONNECTOR
TRAILER
FACTORY
C2
4
3
AFTERMARKET
TRAILER
TOW
CONNECTOR
(8W-54-5)
(8W-15-12)
(8W-15-12)
(8W-15-9) (8W-15-11)
(8W-12-17)
(8W-12-2)
(8W-15-11)
(8W-15-11)
(8W-15-10)
(8W-54-5)
8W - 51 - 6 8W-51 REAR LIGHTING ZG-RHD
J978W-3 ZGR05105
17
FUSE
15A
BATT A6
JUNCTION
BLOCK
10A
FUSE
15
A
RELAY
LAMP
FOG
REAR
85 87
30 86
3 10
C7 C7
L95
18
DG/YL
BATT F61
C7
7 6
C7 C9
11
HEADLAMP
SWITCH
1 AUTO
2 OFF
3 PARK
4 ON
4
3 2
1
15 15
2
366
16
PK/OR
L96
20
LG/RD
Z1
16
BK
Z1
14
BK
Z1
14
BK
G304
A2 C301
L36
18
LG
L36
18
LG/OR
7 C307
1
1
LAMP
OUTAGE
MODULE
G
A
L36
18
LG/OR
L36
18
LG/BK
6 C328
LAMP
FOG
REAR
LEFT RIGHT
REAR
FOG
LAMP
A
G
L36
18
LG/BK
L36
18
LG/OR
C320 6
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
12
BK
S202
S417 S411
4 C328 4 C320
S316
G300
(8W-10-14)
(8W-10-11)
(8W-12-2)
(8W-10-12)
(8W-10-9)
(8W-50-2)
(8W-50-5)
(8W-50-7)
(8W-15-18)
(8W-15-18)
(8W-15-11) (8W-15-9)
(8W-15-11)
(8W-15-11)
ZG-RHD 8W-51 REAR LIGHTING 8W - 51 - 7
ZGR05106 J978W-3
8W-51 REAR LIGHTING
DESCRIPTION AND OPERATION
TAIL LAMPS, REAR LICENSE PLATE LAMPS AND
SIDE MARKER LAMPS
Ci rcui t A6 from fuse 13 i n the Power Di stri buti on
Center (PDC) feeds ci rcui t 366 through fuse 17 i n the
juncti on bl ock. Ci rcui t 366 connects to the headl amp
swi tch.
When the headl amp swi tch i s i n the PARK or LOW
posi ti on, the swi tch connects ci rcui t 366 to ci rcui t
L90. From the headl amp swi tch, ci rcui t L90 branches
to power the front parki ng l amps and rear l i cense
pl ate l amps. Ci rcui t L90 connects to ci rcui ts L21 and
L22. Ci rcui ts L21 and L22 feed the tai l l amps and
si de marker l amps. I f the vehi cl e i s equi pped wi th a
l amp outage modul e, ci rcui t L90 feeds the modul e
and the modul e powers the rear tai l , l i cense pl ate
and si de marker l amps.
The Body Control Modul e (BCM) operates the park
l amps when i t senses unauthori zed entry to the vehi -
cl e whi l e the Vehi cl e Theft Securi ty System i s armed.
When i t sense unauthori zed entry, the BCM ener-
gi zes the park l amp rel ay by provi di ng ground for the
rel ay coi l on ci rcui t L79. Ci rcui t 366 powers the rel ay
coi l and contacts. When the rel ay energi zes, i t con-
nects ci rcui t 366 to ci rcui t L90.
Ci rcui t Z1 provi des a ground for the parki ng
l amps, tai l l amps, and rear l i cense pl ate l amps.
HELPFUL INFORMATION
I f the vehi cl e i s equi pped wi th factory i nstal l ed
trai l er tow, ci rcui t L90 connects to the trai l er tow
harness.
Check fuse 13 i n PDC.
Check fuse 17 i n the juncti on bl ock.
STOP LAMPS AND CHMSL LAMPS
Ci rcui t A250 from fuse 11 i n the Power Di stri bu-
ti on Center (PDC) suppl i es vol tage to ci rcui t L16
through fuse 9 i n the juncti on bl ock. Ci rcui t L16 con-
nects to the stop l amp swi tch.
When the operator presses the brake pedal , the
stop l amp swi tch cl oses and connects ci rcui t L16 to
ci rcui t L50. Ci rcui t L50 connects to ci rcui ts L73, L74
and L87. Ci rcui t L73 and L74 feed the stop l amps.
Ci rcui t L87 powers the Center Hi gh Mounted Stop
Lamps (CHMSL). Ci rcui t Z1 provi des a ground for
the stop l amps and CHMSL l amps.
I f the vehi cl e i s equi pped wi th a l amp outage mod-
ul e, ci rcui t L50 connects to the modul e. The l amp
outage modul e powers ci rcui t L73, L74 and L87.
REAR FOG LAMPS
The rear fog l amps are powered by the rear fog
l amp rel ay on ci rcui t L36. The rel ay coi l and contacts
are powered by ci rcui t L95 from fuse 15 i n the fuse
bl ock. The rel ay coi l ground i s control l ed by the head-
l amp and rear fog l amp swi tches on ci rcui t L96.
BACK-UP LAMPS
I n the RUN posi ti on, the i gni ti on swi tch connects
ci rcui t A1 from fuse 8 i n the Power Di stri buti on Cen-
ter (PDC) to ci rcui t A22. Ci rcui t A22 powers ci rcui t
F83 through fuse 6 i n the juncti on bl ock
Ci rcui t F83 suppl i es power to the PARK/NEU-
TRAL posi ti on swi tch. When the operator puts the
transmi ssi on i n REVERSE, the swi tch connects ci r-
cui t F83 to ci rcui t L10. Ci rcui t L10 feeds the back-up
l amps. Ci rcui t Z1 provi des ground for the back-up
l amps.
HELPFUL INFORMATION
Check fuse 8 i n the PDC and fuse 6 i n the junc-
ti on bl ock.
Check for conti nui ty across the back-up l amp
swi tch when i t i s cl osed.
LAMP OUTAGE MODULE (LOM)
The Lamp Outage Modul e (LOM) determi nes i f a
rear l i ghti ng l amp i s not operati ng. When the i gni -
ti on swi tch i s i n the START or RUN posi ti on, ci rcui t
A1 from fuse 8 i n the Power Di stri buti on Center
(PDC) connects to ci rcui t A21. Ci rcui t A21 feeds ci r-
cui t F87 through fuse 5 i n the juncti on bl ock. Ci r-
cui ts F87 feeds the LOM.
Ci rcui t G46 from the LOM connects to the Vehi cl e
I nformati on Center (VI C). When the LOM senses a
i noperati ve l amp, the VI C di spl ays the data to the
vehi cl e operator.
Ci rcui t L90 whi ch feeds the tai l l amps and si de
marker l amps, connects to the LOM. From the LOM,
ci rcui t L90 conti nues to the l i cense pl ate l amps. Ci r-
cui ts L21 and L22 from the LOM power the tai l
l amps and si de marker l amps.
Ci rcui t L50 from the stop l amp swi tch connects to
the LOM. From the LOM, ci rcui ts L73 and L74
power the stop l amps and ci rcui t L87 powers the
Center Hi gh Mounted Stop Lamps (CHMSL).
Ci rcui t Z1 grounds the LOM.
8W - 51 - 8 8W - 51 REAR LIGHTING ZG
8W-52 TURN SIGNALS
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Component Page
Aftermarket Trai l er Tow Connector . . . . . . . 8W-52-7
El ectroni c Fl asher . . . . . . . . . . . . . . . . 8W-52-2, 4, 6
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 4, 6
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 6
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 8
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 7
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 6
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-52-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-52-2, 4, 6, 7
Left Front Park Lamp . . . . . . . . . . . . . . . . . 8W-52-3
Left Front Si de Marker Lamp . . . . . . . . . . . 8W-52-3
Left Front Turn Si gnal . . . . . . . . . . . . . . . . 8W-52-8
Left Front Turn Si gnal Lamp . . . . . . . . . . . 8W-52-3
Left Park Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
Left Rear Turn Si gnal Lamp . . . . . . . . . . 8W-52-5, 7
Left Si de Repeater . . . . . . . . . . . . . . . . . . . 8W-52-8
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-52-8
Ri ght Front Park Lamp . . . . . . . . . . . . . . . 8W-52-3
Ri ght Front Si de Marker Lamp . . . . . . . . . . 8W-52-3
Ri ght Front Turn Si gnal . . . . . . . . . . . . . . . 8W-52-8
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . 8W-52-3
Ri ght Park Lamp . . . . . . . . . . . . . . . . . . . . 8W-52-8
Ri ght Rear Turn Si gnal Lamp . . . . . . . . . 8W-52-5, 7
Ri ght Si de Repeater . . . . . . . . . . . . . . . . . . 8W-52-8
Component Page
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 8
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 8
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
S149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 6
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 6
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 6
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 7
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 7
S408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 8
S409 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 8
S410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
S411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 7
S413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
S414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
S415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
S417 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 7
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . 8W-52-5
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . 8W-52-5
Turn Si gnal /Hazard Warni ng Swi tch . . 8W-52-2, 4, 6
Vehi cl e I nformati on Center . . . . . . . . . 8W-52-2, 4, 6
ZG 8W - 52 TURN SIGNALS 8W - 52 - 1
11 16
17 13
L65
18
LG/DB
TO
C234
C150
TO
TN/DB
18
L64
13
FUSE
15A
1 2
15A
FUSE
6
3 4 5
ELECTRONIC
FLASHER
FUSED
B(+)
FUSED
IGN.
(RUN)
GROUND
HAZARD
SIGNAL SIGNAL
TURN
4 1 5 C7 C5 C5
BATT A7 RUN A22
L5
18
OR/BK
L12
18
VT/TN Z1
18
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
S220
S216
S202
2 C301
G304
A
(8W-52-3)
B
(8W-52-3)
6
INSTRUMENT
CLUSTER
L65
18
LG/DB
JUNCTION
BLOCK
C1
11 1
C4
7
L64
18
TN/DB
L64
18
TN/DB
JUNCTION
BLOCK
2 1
LEFT
TURN
SIGNAL
INDICATOR INDICATOR
SIGNAL
TURN
RIGHT
0 OFF
2 LT TURN
1 RT TURN
SWITCH
WARNING
HAZARD
SIGNAL/
TURN
4 HAZARD
2 1
4 0
VEHICLE
INFORMATION
CENTER
TO
OR/BK
18
L5
SWITCH)
(PART OF
MULTI-FUNCTION
5 C4
G
(8W-52-8)
TO
S412
GAS DIESEL
(8W-46-6)
(8W-12-2)
(8W-10-8) (8W-10-12)
(8W-12-2)
(8W-40-4)
(8W-15-18)
(8W-15-18)
(8W-15-17)
(8W-15-17)
(8W-12-6) (8W-12-11)
(8W-52-8)
8W - 52 - 2 8W-52 TURN SIGNALS ZG-RHD
J978W-3 ZGR05201
L64
18
TN/DB
L64
18
TN/DB
G
A
Z1
18
BK
A
B
Z1
18
BK
Z1
18
BK
Z1
18
BK
A
B
Z1
16
BK
S109
3 C102
L90
18
DB/RD
S149
L90
18
DB/RD
S410
L64
18
TN/DB
S408
LAMP
SIGNAL
TURN
FRONT
LEFT RIGHT
FRONT
TURN
SIGNAL
LAMP
C150 1
S413
TN/DB
18
L64
S415
DB/RD
18
L90
S414
DB/RD
18
L90
C150 3
B
A
BK
18
Z1
BK
18
Z1
BK
18
Z1
B
A
BK
18
Z1
A
G
TN/DB
18
L64
TN/DB
18
L64
TN/DB
18
L64
Z1
14
BK
G106
S104
A
(8W-52-2)
FROM
B
(8W-52-2)
JUNCTION
BLOCK
FROM
LAMP
MARKER
SIDE
FRONT
LAMP
PARK
FRONT FRONT
PARK
LAMP
FRONT
SIDE
MARKER
LAMP
LEFT
LEFT RIGHT
RIGHT
L65
18
LG/DB
1 C102
F10 C234
HAZARD WARNING SWITCH
TURN SIGNAL/
(8W-15-5)
(8W-12-15) (8W-12-15)
(8W-15-7)
(8W-15-7)
ZG-RHD 8W-52 TURN SIGNALS
GAS ENGINES
8W - 52 - 3
ZGR05202 J978W-3
12 15
17 13
L61
18
DG
TO
C307 C307
TO
TN
18
L60
2
15A
FUSE
6
3 4
FUSED
IGN.
(RUN)
HAZARD
SIGNAL SIGNAL
TURN
1 5 C7 C5
RUN A22
L5
18
OR/BK
L12
18
VT/TN
C
(8W-52-5)
D
(8W-52-5)
JUNCTION
BLOCK
FLASHER
ELECTRONIC
4
VEHICLE
INFORMATION
CENTER
L5
18
OR/BK
2 1
0 OFF
2 LT TURN
1 RT TURN
SWITCH
WARNING
HAZARD
SIGNAL/
TURN
4 HAZARD
2 1
4 0
(PART OF
MULTI-FUNCTION
SWITCH)
(8W-46-6)
(8W-52-2)
(8W-10-8)
(8W-12-2)
(8W-12-6)
8W - 52 - 4 8W-52 TURN SIGNALS ZG-RHD
J978W-3 ZGR05203
L61
18
DG
L61
18
LG
L61
18
LG
L60
18
TN
L60
18
TN
L60
18
TN
3
5 C328
4 C307
G
A
LEFT
REAR
TURN
SIGNAL
LAMP
G302
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
12
BK
S314
S411
4 C328 C320 4
S417
S316
BK
12
Z1
BK
18
Z1
BK
18
Z1
BK
18
Z1
G300
LAMP
SIGNAL
TURN
REAR
RIGHT
A
G
C320 5
LG
18
L61
TN
18
L60
LG
18
L61
4
L61
18
LG
C372 5
1 1
RELAY
TURN
LEFT
TOW
TRAILER TRAILER
TOW
RIGHT
TURN
RELAY
C
(8W-52-4)
D
(8W-52-4)
TURN
SIGNAL/
HAZARD
WARNING
SWITCH
TO TO
SWITCH
WARNING
HAZARD
SIGNAL/
TURN
(8W-15-12)
(8W-15-12)
(8W-15-9) (8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-54-3) (8W-54-3)
ZG-RHD 8W-52 TURN SIGNALS
FACTORY TRAILER TOW
8W - 52 - 5
ZGR05204 J978W-3
12 15
17 13
13
FUSE
15A
1 2
15A
FUSE
6
3 4 5
ELECTRONIC
FLASHER
FUSED
B(+)
FUSED
IGN.
(RUN)
GROUND
HAZARD
SIGNAL SIGNAL
TURN
4 1 5 C7 C5 C5
BATT A7 RUN A22
L5
18
OR/BK
L12
18
VT/TN
Z1
18
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
S220
S216
S202
2 C301
G304
L61
18
DG
E
(8W-52-7)
TO
C307
F
(8W-52-7)
TO
C307
L60
18
TN
JUNCTION
BLOCK
2 1
SWITCH
WARNING
HAZARD
SIGNAL/
TURN
2 1
4 0
VEHICLE
INFORMATION
CENTER
TO
OR/BK
18
L5
MULTI-FUNCTION
SWITCH)
(PART OF
4 HAZARD
2 LT TURN
0 OFF
1 RT TURN
(8W-46-6)
(8W-12-2)
(8W-10-8) (8W-10-12)
(8W-15-18)
(8W-15-18)
(8W-15-17)
(8W-15-17)
(8W-12-6) (8W-12-11)
8W - 52 - 6 8W-52 TURN SIGNALS ZG-RHD
J978W-3 ZGR05205
L61
18
DG
L61
18
LG
L60
18
TN
L60
18
TN
L60
18
TN
L60
18
TN
S313
C
CONNECTOR
TOW
TRAILER
AFTERMARKET
3
5 C328
4 C307
G
A
LEFT
REAR
TURN
SIGNAL
LAMP
G302
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
12
BK
S314
S411
4 C328 C320 4
S417
S316
BK
12
Z1
BK
18
Z1
BK
18
Z1
BK
18
Z1
G300
LAMP
SIGNAL
TURN
REAR
RIGHT
A
G
C320 5
TN
18
L60
LG
18
L61
E
(8W-52-6)
F
(8W-52-6)
C307
C14
8
20A
FUSE
8
BATT A250
JUNCTION
BLOCK
D
S315
F70
14
PK/BK
F70
14
PK/BK
TURN
SIGNAL/
HAZARD
WARNING
SWITCH
TO TO
SWITCH
WARNING
HAZARD
SIGNAL/
TURN
(8W-54-4)
(8W-15-12)
(8W-15-12)
(8W-15-9) (8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-12-8)
(8W-10-10)
(8W-12-2)
(8W-12-8)
ZG-RHD 8W-52 TURN SIGNALS
AFTERMARKET TRAILER TOW
8W - 52 - 7
ZGR05206 J978W-3
A
(8W-52-2)
L65
18
LG/DB
L65
18
LG/DB
L65
18
LG/DB
S409
C102 1
L65
18
LG/DB
2
1
1
2
REPEATER
SIDE
LEFT LEFT
FRONT
TURN
L65
18
LG/DB
F10 C234
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
S109
3 C102
S149
Z1
16
BK
G109
LAMP
PARK
LEFT
1
2
SIGNAL
Z1
18
BK
L90
18
DB/RD
L90
18
DB/RD
S147
L90
18
DB/RD
S103
L90
18
DB/RD
2 C102
2
1
RIGHT
PARK
LAMP
L90
18
DB/RD
L90
18
DB/RD
L90
18
DB/RD
C150 2
S150
S152
C150 3
BK
18
Z1
Z1
18
BK
BK
18
Z1
18
Z1
BK
Z1
16
BK
G106
S104
Z1
18
BK
L64
18
LG/DB
C150 1
LG/DB
18
L64
LG/DB
18
L64
LG/DB
18
L64
S408
G
(8W-52-2)
TURN
SIGNAL/
HAZARD
WARNING
FROM
JUNCTION
BLOCK
FROM
RIGHT
SIDE
REPEATER
SIGNAL
TURN
FRONT
RIGHT
1
2
2
1
87
(IN JB)
RELAY
LAMP
PARK
SWITCH
(8W-50-7)
(8W-50-8)
8W - 52 - 8 8W-52 TURN SIGNALS
DIESEL ENGINES
ZG-RHD
J978W-3 ZGR05207
8W-52 TURN SIGNALS
DESCRIPTION AND OPERATION
ELECTRONIC FLASHER RELAY
The el ectroni c fl asher rel ay i n the juncti on bl ock
suppl i es battery vol tage to the turn si gnal /hazard
swi tch ci rcui try i n the mul ti -functi on swi tch. When
the i gni ti on swi tch i s OFF, the hazard fl ashers wi l l
operate but the turn si gnal s wi l l not.
Ci rcui t A7 from fuse 15 i n the Power Di stri buti on
Center (PDC) powers the el ectroni c fl asher through
fuse 13 i n the juncti on bl ock.
I n the RUN posi ti on, the i gni ti on swi tch connects
ci rcui t A1 from fuse 8 i n the Power Di stri buti on Cen-
ter (PDC) to ci rcui t A22. Ci rcui t A22 feeds the fl asher
rel ay through fuse 6 i n the juncti on bl ock. Ci rcui t Z1
provi des ground for the rel ay.
Ci rcui t L5 from the fl asher rel ay connects to the
mul ti -functi on swi tch to suppl y power to the turn si g-
nal ci rcui ts. The mul ti -functi on swi tch connects to
the ri ght rear turn si gnal l amps on ci rcui t L60 and
the l eft rear turn si gnal l amp on ci rcui t L61. Ci rcui t
L64 from the swi tch feeds the ri ght front turn si gnal
l amp and si de marker l amp. Ci rcui t L65 feeds the
l eft front turn si gnal l amp and si de marker l amp.
Ci rcui t L12 from the fl asher rel ay connects to the
mul ti -functi on swi tch to suppl y power to the hazard
fl asher ci rcui ts. The mul ti -functi on swi tch connects
to the rear turn si gnal l amps on ci rcui ts L60 and L61
and the front turn si gnal and si de marker l amps on
ci rcui ts L64 and L65.
TURN SIGNALS
When the operator sel ects the ri ght turn si gnal ,
the mul ti -functi on swi tch connects ci rcui t L5 from
the fl asher rel ay to ci rcui ts L60 and L64. Ci rcui t L64
feeds the ri ght front turn si gnal l amp and si de
marker l amp. Ci rcui t L60 feeds the ri ght rear turn
si gnal l amp. Ci rcui t L64 al so spl i ces to power the
ri ght turn si gnal i ndi cator l amp i n the i nstrument
cl uster.
When the operator sel ects the l eft turn si gnal , the
mul ti -functi on swi tch connects ci rcui t L5 from the
fl asher rel ay to ci rcui ts L61 and L65. Ci rcui t L61
feeds the l eft rear turn si gnal l amp and si de marker
l amp. Ci rcui t L65 feeds the l eft front turn si gnal
l amp. Ci rcui t L65 al so spl i ces to power the l eft turn
si gnal i ndi cator l amp on the i nstrument cl uster.
Ci rcui t Z1 provi des ground for the turn si gnal
l amps.
HAZARD FLASHERS
When the operator sel ects the hazard fl ashers, the
mul ti -functi on swi tch ci rcui t L12 from the fl asher
rel ay ci rcui ts L60, L61, L64 and L65.
Ci rcui t L61 feeds the l eft rear turn si gnal l amp.
Ci rcui t L60 feeds the ri ght rear turn si gnal l amp.
Ci rcui t L65 feeds the l eft front turn si gnal l amp, si de
marker l amp and the i nstrument cl uster i ndi cator
l amp. Ci rcui t L64 feeds the ri ght front turn si gnal
l amp, si de marker l amp and the i nstrument cl uster
i ndi cator l amp.
Ci rcui t Z1 provi des ground for the hazard fl asher
l amps.
ZG 8W - 52 TURN SIGNALS 8W - 52 - 9
8W-53 WIPERS
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Page
Body Control Modul e . . . . . . . . . . . . . . . . 8W-53-2, 3
Ci rcui t Breaker 1 . . . . . . . . . . . . . . . . . . . . 8W-53-2
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3, 5
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
I ntermi ttent Wi per Rel ay . . . . . . . . . . . . . . 8W-53-3
I ntermi ttent Wi per Swi tch . . . . . . . . . . . 8W-53-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 4
Li ft- Gate Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-53-5
Li ft- Gl ass Ajar Swi tch . . . . . . . . . . . . . . . . 8W-53-5
Rear Washer Pump Motor . . . . . . . . . . . . . . 8W-53-5
Rear Wi per Modul e . . . . . . . . . . . . . . . . . . . 8W-53-4
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-53-4
Component Page
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . 8W-53-4
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3, 5
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
Vehi cl e I nformati on Center . . . . . . . . . . . . . 8W-53-5
Wi ndshi el d Washer Pump Motor . . . . . . . . . 8W-53-2
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . 8W-53-2, 3
Wi per Fl ui d Level Sensor . . . . . . . . . . . . . . 8W-53-5
ZG 8W - 53 WIPERS 8W - 53 - 1
3
4
1 2
4 LOW
2 DELAY
3 HIGH
INTERMITTENT
WIPER
SWITCH
0 OFF
1 WASH
5 PARK
RUN-ACC A31
20A
1
BREAKER
CIRCUIT
7 12 C1 C4
C6 1
TO
S122
F86
16
LG/RD
F86
16
LG/BK
V6
16
DB
A
(8W-53-3)
FROM
RELAY
WIPER
INTERMITTENT
C2 18 1 C1 C2 17
BODY
CONTROL
MODULE
WIPER
SWITCH
DELAY
SENSE SIGNAL
SWITCH
WIPER
WINDSHIELD WASHER
SWITCH
OUTPUT
V50
18
LG/WT
V51
18
WT
V11
18
TN/BK
V11
18
TN/BK
C234 F1
V11
18
TN/BK
A
B
Z2
18
BK
G109
Z2
12
BK
S121
MOTOR
PUMP
WASHER
WINDSHIELD
B
(8W-53-3)
JUNCTION
BLOCK
M
0 1
5 6
C235
BR/WT
BR/WT
5
V3
18
16
14
V3
18
WIPER
MOTOR
WINDSHIELD
6
RD/YL
V4
18
C234 F4
RD/YL
V4
18
BR/WT
V3
9
18
2
3
4
5
0 0
M
8 7
DB
16
V6
DB
16
V6
16
DB
V6
F18 C234
MULTI-FUNCTION
SWITCH)
(PART OF
S121
BK
12
Z2
G109
BK
18
Z2
4
(8W-52-8)
(8W-15-4)
(8W-15-5)
(8W-53-3)
(8W-12-2)
(8W-10-9)
(8W-15-4)
(8W-15-5)
(8W-15-4)
(8W-15-5)
(8W-45-7)
(8W-12-4)
8W - 53 - 2 8W-53 WIPERS ZG-RHD
J978W-3 ZGR05301
TO
C234
JUNCTION
BLOCK
FROM
V6
16
DB
C1 C5
C2 C3
F86
16
LG/RD
S122
V66
18
VT/WT
V66
18
VT/WT
V66
16
VT/WT
17
C235
13
4 C2
SENSE
SWITCH
PARK
WIPER BODY
CONTROL
MODULE
4
5 6
M
1 2
4 LOW
3 HIGH
2 PARK
1 RUN
MOTOR
WIPER
WINDSHIELD
V66
18
VT/WT
F86
16
LG/RD
5 6
INTERMITTENT
WIPER
SWITCH
V4
18
RD/YL
V4
18
RD/YL
F4 C234
V3
18
BR/WT
V3
18
BR/WT
C235
16
14
1 2
4
3
Z2
18
BK
Z2
12
BK
S121
G109
RELAY
WIPER
INTERMITTENT
S120
B
(8W-53-2)
A
(8W-53-2)
V18
20
YL/LG
10
C235
20
V18
20
YL/LG
F86 16LG/RD
F86
16
LG/RD
BODY
CONTROL
MODULE
INTERMITTENT
CONTROL
RELAY
WIPER
C2 23
C4
(IN PDC)
(8W-45-7)
(8W-15-4)
(8W-15-5)
(8W-15-4)
(8W-15-5)
(8W-53-2)
(8W-45-7)
ZG-RHD 8W-53 WIPERS 8W - 53 - 3
ZGR05302 J978W-3
8
FUSE
20A
BATT A250
4 1
2
10A
FUSE
3
C10 C14
8
F70
14
PK/BK
F70
14
PK/BK
F70
16
PK/BK
S315
7
C323
LIFTGLASS OTHERS
F70
16
PK/BK
F70
16
PK/BK
F70
16
PK/BK
S336
1
3
4
FUSED
B (+)
5
INTERMITTENT WASH
2
LIFT-GATE
AJAR
6
MODULE
WIPER
REAR
1
2
3 4
0 1
V23
18
BR/PK
V13
18
BR/LG
V13
18
BR/LG
V13
18
BR/LG
V24
18
BR/OR
V24
18
BR/OR
V24
18
BR/OR
V20
18
WT/BK
V20
18
BK/WT
V20
18
BK/WT
6 C307 3 C305
4
V20
18
WT/BK
V20
18
WT/BK
F17 C234
REAR
WASHER
PUMP
MOTOR
TO
REAR
WIPER
MOTOR
F70
16
PK/BK
1 6 4 C324
TO
S329
TO
S328
Z1
14
BK
G78
20
TN/BK
RUN-ACC A31
1 ON
2 INTERMITTENT
REAR
WIPER/
WASHER
SWITCH
0 OFF
D
(8W-53-5)
C
(8W-53-5)
2 1
0
3
4
E
(8W-53-5)
M
JUNCTION
BLOCK
2
4 9 11
(8W-10-9) (8W-10-10)
(8W-12-8)
(8W-12-8)
(8W-12-4) (8W-12-8)
8W - 53 - 4 8W-53 WIPERS ZG-RHD
J978W-3 ZGR05303
FROM
MODULE
WIPER
REAR REAR
WIPER
MODULE
FROM
Z1
14
BK
G78
20
TN/BK
G78
20
TN/BK
Z1
20
BK
1
2
SWITCH
AJAR
GLASS
LIFT- LIFT-
GATE
AJAR
SWITCH
2
1
S329
S328
Z1
12
BK
Z1
12
BK
Z1
12
BK
G300
S316
3
C325
FROM
C234
V20
18
WT/BK
1
2
MOTOR
PUMP
WASHER
REAR
Z2
18
BK
Z2
18
BK
G109
Z2
16
BK
A
B
13
VEHICLE
INFORMATION
CENTER
G29
20
BK/TN
G29
16
BK/TN
F7 C234
S121
Z1
20
BK
WASHER
FLUID
LEVEL
SENSE
C
(8W-53-4)
D
(8W-53-4)
E
(8W-53-4)
SENSOR
LEVEL
FLUID
WIPER
G78
20
TN/BK
M
2
(8W-44-14)
(8W-45-11)
(8W-15-10)
(8W-15-11)
(8W-15-11)
(8W-15-4)
(8W-15-5)
(8W-46-6)
(8W-15-4)
(8W-15-5)
ZG-RHD 8W-53 WIPERS 8W - 53 - 5
ZGR05304 J978W-3
8W-53 WIPERS
DESCRIPTION AND OPERATION
INTERMITTENT WIPER OPERATION
I n the ACCESSORY or RUN posi ti on, the i gni ti on
swi tch connects ci rcui t A1 from fuse 8 i n the PDC to
ci rcui t A31. Ci rcui t A31 powers ci rcui t F86 through
the ci rcui t breaker i n cavi ty 1 of the juncti on bl ock.
Ci rcui t F86 suppl i es power to the i ntermi ttent wi per
swi tch.
When the operator sel ects LOW speed wi per oper-
ati on, the swi tch connects ci rcui t F86 to ci rcui t V3.
Ci rcui t V3 powers the wi per motor l ow speed brush.
When the operator sel ects HI GH speed wi per oper-
ati on, the swi tch connects ci rcui t F86 to ci rcui t V4.
Ci rcui t V4 powers the wi per motor hi gh speed brush.
When the operator sel ects i ntermi ttent wi per oper-
ati on the wi per swi tch sends a si gnal s to the Body
Control Modul e (BCM) on ci rcui t V51. The BCM
determi nes the amount of del ay sel ected on ci rcui t
V50 from the swi tch.
After determi ni ng the amount of del ay sel ected,
the BCM peri odi cal l y energi zes the i ntermi ttent
wi per rel ay on ci rcui t V18. Ci rcui t F86 from the ci r-
cui t breaker i n the juncti on bl ock powers the rel ay
coi l and contacts. Ci rcui t F86 i s HOT when the i gni -
ti on swi tch i s i n the ACCESSORY or RUN posi ti on.
When the i ntermi ttent wi per rel ay energi zes i t
powers ci rcui t V6. Ci rcui t V6 connects to ci rcui t V3
through the i ntermi ttent wi per swi tch. Ci rcui t V3
powers the wi per motor l ow speed brush. Ci rcui t Z2
provi des ground for the brush. When not energi zed,
the rel ay connects ci rcui t F86 to ci rcui t V66. Ci rcui t
V66 connects to the park swi tch i n the i ntermi ttent
wi per motor and the BCM.
REAR WIPER/WASHER
The rear wi per and washer system uses a swi tch
assembl y l ocated i n the ri ght swi tch pod.
When the i gni ti on swi tch i s i n the ACCESSORY or
RUN posi ti on, i t connects ci rcui t A1 from fuse 8 i n
the Power Di stri buti on Center (PDC) to ci rcui t A31.
Ci rcui t A31 powers ci rcui t V23 through fuse 3 i n the
juncti on bl ock. Ci rcui t V23 suppl i es power for the
rear wi per/wash swi tch.
Ci rcui t A250 from fuse 11 i n the PDC powers ci r-
cui t F70 through fuse 8 i n the juncti on bl ock. Ci rcui t
F70 powers the rear wi per motor and the control
modul e l ocated i nternal to the motor assembl y.
When the operator sel ects the ON posi ti on, power
i s suppl i ed through the swi tch to ci rcui t V13. The
V13 ci rcui t connects from the swi tch to the rear
wi per control modul e.
The modul e processes thi s si gnal and suppl i es
power to the wi per motor. Ground for the wi per
motor i s suppl i ed on ci rcui t Z1.
When the swi tch i s pl aced i n the DELAY posi ti on,
power i s suppl i ed from the swi tch to the motor con-
trol on ci rcui t V24. The modul e processes thi s si gnal
and connects the motor to vol tage. The amount of
DELAY i s control l ed by the posi ti on of the rear wi per
swi tch.
When the WASH swi tch i s acti vated, power i s
passed through the swi tch to ci rcui t V20. Thi s ci rcui t
i s doubl e cri mped at the swi tch. One branch of the
ci rcui t connects to the rear wi per control modul e. The
other branch connects to the rear washer pump
motor.
An addi ti onal i nput to the rear wi per control mod-
ul e i s suppl i ed on ci rcui t G78. Thi s ci rcui t i s con-
nected to the l i ftgate and l i ftgl ass ajar swi tches.
Ci rcui t G78 si gnal s the control when the l i ftgate or
l i ftgl ass opens.
When the l i ftgate i s ajar the wi per control modul e
wi l l not al l ow the rear wi per or washer to operate.
HELPFUL INFORMATION
Check fuses 8 and 11 i n the PDC
Check fuses 3 and 8 i n the juncti on bl ock
Check the operati on of the l i ftgate ajar swi tch
LOW WASHER FLUID LEVEL SENSOR
When the swi tch i n the l ow washer fl ui d sensor
cl oses, i t connects ci rcui t G29 from the Vehi cl e I nfor-
mati on Center (VI C) to ground on ci rcui t Z2. The
VI C di spl ays the l ow washer fl ui d message.
8W - 53 - 6 8W - 53 WIPERS ZG
8W-54 TRAILER TOW
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Page
Aftermarket Trai l er Tow Connector . . . . . 8W-54-4, 5
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . . 8W-54-5
Ci rcui t Breaker 15a . . . . . . . . . . . . . . . . . . 8W-54-2
Factory Trai l er Tow Connector . . . . 8W-54-2, 3, 4, 5
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 4, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-54-5
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . 8W-54-2, 4, 5
Lamp Outage Modul e . . . . . . . . . . . . . 8W-54-3, 4, 5
Park/Neutral Posi ti on Swi tch . . . . . . . . . 8W-54-2, 4
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 4
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-5
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-4
Component Page
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 4, 5
S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-54-5
Trai l er Brake Provi si on . . . . . . . . . . . . . . 8W-54-2, 4
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . 8W-54-2, 5
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . 8W-54-3
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . 8W-54-3
Trai l er Tow Stop Lamp Rel ay . . . . . . . . . 8W-54-2, 3
Turn Si gnal /Hazard Warni ng Swi tch . . . . 8W-54-3, 4
ZG 8W - 54 TRAILER TOW 8W - 54 - 1
20A
FUSE
8
C14 8
F70
14
PK/BK
F70
16
PK/BK
F70
16
PK/BK
S315
6 C372
A
B
15A
BREAKER
CIRCUIT
F70
16
PK/BK
F70
16
PK/BK
F70
18
PK/BK
6
S331
4
1
SWITCH
POSITION
NEUTRAL
PARK/
2 C3
C14 1
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
3
C331
3 C372
S311
6 C131
7
CONNECTOR
TOW
TRAILER
FACTORY
JUNCTION
BLOCK
JUNCTION
BLOCK
BATT A250
BREAKER
CIRCUIT
TOW
TRAILER
3
F70
PK/BK
16
RELAY
LAMP
TRAILER
TOW
STOP
(8W-54-3)
(8W-12-2)
(8W-12-2)
(8W-10-10)
(8W-12-17)
(8W-44-7)
(8W-12-8)
(8W-12-8)
8W - 54 - 2 8W-54 TRAILER TOW ZG-RHD
J978W-3 ZGR05401
2
1
3
5 4
3
1
2 2
1
3
Z1
18
BK
Z1
18
BK
Z1
18
BK
TRAILER
TOW
RIGHT
TURN
RELAY RELAY
TURN
LEFT
TOW
TRAILER
TRAILER
TOW
STOP
LAMP
RELAY
L60
18
TN/OR
L60
18
TN
L61
18
LG/OR
L61
18
LG
F70
16
PK/BK
F70
16
PK/BK
F70
18
PK/BK
Z1
12
BK
Z1
12
BK
S330
5
6
9
1
4
5
6 C331
4
CONNECTOR
TOW
TRAILER
FACTORY
G302
Z1
12
BK
Z1
12
BK
Z1
12
BK
S314
8 C372
L50
18
WT/TN
L50
18
WT/TN
1 C372
2
STOP
LAMP
SWITCH
OUTPUT
LAMP
OUTAGE
MODULE
L60
18
TN
L60
18
TN
L60
18
TN
4
5
12 15
L61
18
LG
L61
18
LG
L61
18
DG
C307 3
4
94 18DG
95 18PK 95 18PK
94 18DG
S331
SWITCH
WARNING
HAZARD
SIGNAL/
TURN
5 4 5 4
C2
(8W-52-5)
(8W-54-2)
(8W-51-3)
(8W-15-12)
(8W-15-12)
ZG-RHD 8W-54 TRAILER TOW 8W - 54 - 3
ZGR05402 J978W-3
20A
FUSE
8
C14 8
F70
14
PK/BK
F70
18
PK/BK
S315
LAMP
OUTAGE
MODULE
12
D A C
L50
18
WT/TN
2
STOP
LAMP
SWITCH
OUTPUT
L60
18
TN
L60
18
TN
L60
18
TN
4 C307
CONNECTOR
TOW
TRAILER
FACTORY
B40
12
LB
B40
12
LB
B40
12
LB
8 C331
7 C372
TRAILER
BRAKE
PROVISION
2
1
SWITCH
POSITION
NEUTRAL
PARK/
2 C3
C14 1
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
L10
18
BR/LG
3 C331
3 C372
S311
6 C131
7
S313
BATT A250
JUNCTION
BLOCK
JUNCTION
BLOCK
TURN
SIGNAL/
HAZARD
WARNING
SWITCH
AFTERMARKET
TRAILER
CONNECTOR
TOW
C2
(8W-52-5)
(8W-12-2)
(8W-12-2)
(8W-10-10)
(8W-52-7) (8W-12-17)
(8W-44-6)
(8W-51-3)
(8W-12-8)
(8W-12-8)
8W - 54 - 4 8W-54 TRAILER TOW ZG-RHD
J978W-3 ZGR05403
SWITCH
LAMP
STOP
5
L50
18
WT/TN
L50
18
WT/TN
S312
12
C305
3
6 7 8 2
L50
18
L50
18
WT/TN
L50
18
WT/TN
L50
18
WT/TN
5 4 3
LAMP
OUTAGE
MODULE
L90
18
DB/RD
L90
18
DB/RD
L90
18
DB/RD
C13
4
C8 10
16
SWITCH
HEADLAMP
L90
20
DB/RD
OUTPUT
RELAY
LAMP
PARK PARK
LAMP
RELAY
OUTPUT OUTPUT
RELAY
LAMP
PARK
OUTPUT
SWITCH
LAMP
STOP STOP
LAMP
SWITCH
OUTPUT
STOP
LAMP
SWITCH
OUTPUT
STOP
LAMP
SWITCH
OUTPUT
PARK
LAMP
RELAY
OUTPUT
L90
18
DB/RD
L90
18
DB/RD
L90
18
DB/RD
L90
18
DB/RD
B 3
2 C331
2 C372
CONNECTOR
TOW
TRAILER
FACTORY AFTERMARKET
TRAILER
TOW
CONNECTOR
PK/BK
14
F70
PK/BK
16
F70
S315
A
TRAILER
TOW
CIRCUIT
BREAKER
B
15A
PK/BK
16
F70
20A
FUSE
8
C14
8
JUNCTION
BLOCK
BATT A250
6 C331
F70
18
PK/BK
4
JUNCTION
BLOCK
FACTORY AFTERMARKET
CIRCUIT
BREAKER
C372 6
F70
16
PK/BK
9
C1 C1 C1 C1 C1 C1 C1
C2
WT/TN
(8W-51-3)
(8W-51-6)
(8W-12-2)
(8W-10-10)
(8W-12-2)
(8W-12-8)
(8W-12-8)
(8W-50-7)
(8W-70-5)
(8W-33-2)
ZG-RHD 8W-54 TRAILER TOW 8W - 54 - 5
ZGR05404 J978W-3
8W-54 TRAILER TOW
GENERAL INFORMATION
INTRODUCTION
Two trai l er tow packages are avai l abl e; a factory
i nstal l ed package and a package wi th after-market
provi si ons. Thi s secti on provi des separate wi ri ng di a-
grams for each.
DESCRIPTION AND OPERATION
TRAILER TOW FACTORY INSTALLED
The factory i nstal l ed trai l er tow system i n thi s
vehi cl e uses three rel ays and a ci rcui t breaker al ong
wi th the trai l er tow wi ri ng connector.
Ci rcui t A250 from fuse 11 i n the Power Di stri bu-
ti on Center (PDC) powers ci rcui t F70 through fuse 8
i n the juncti on bl ock. Ci rcui t F70 suppl i es battery
vol tage for the trai l er tow ci rcui t breaker and the
contact si de of the stop l amp rel ay
The trai l er tow ci rcui t breaker i s taped to the
trai l er tow harness l ocated i n the l eft rear quarter
panel .
STOP LAMP RELAY
Power for the coi l si de of the stop l amp rel ay i s
suppl i ed by ci rcui t L50. Thi s ci rcui t connects to the
stop l amps. Ground for the coi l si de i s suppl i ed on
ci rcui t Z1.
When the operator presses the brake pedal , vol tage
fl ows through the coi l of the rel ay to ground causi ng
the contacts i n the rel ay to connect ci rcui ts F70 and
95.
Ci rcui t 95 connects to the l eft and ri ght turn si gnal
rel ays. Vol tage fl ows through the cl osed contacts i n
the rel ays to the trai l er tow connector.
RIGHT TURN RELAY
Power for the coi l si de of the ri ght turn rel ay i s
suppl i ed by ci rcui t L60. Thi s ci rcui t connects to the
ri ght si de turn si gnal l amps. Ground for the coi l si de
of the rel ay i s suppl i ed on ci rcui t Z1.
When the operator turns the ri ght turn si gnal ON,
power fl ows through the coi l i n the rel ay to ground
causi ng the contacts i n the rel ay to swi tch from the
normal l y CLOSED posi ti on to connect ci rcui ts 94 and
L60.
Ci rcui t 94 i s the feed for the contact si de of the
rel ay. Ci rcui t L60 connects from the rel ay to the
trai l er tow connector.
Ci rcui t 94 i s fed power through the normal l y
CLOSED si de of the stop l amp rel ay by ci rcui t F70.
Ci rcui t F70 i s HOT at al l ti mes and protected by a
ci rcui t breaker l ocated i n the ri ght rear quarter
panel .
LEFT TURN RELAY
Power for the coi l si de of the l eft turn rel ay i s sup-
pl i ed by ci rcui t L61. Thi s ci rcui t connects to the l eft
si de turn si gnal l amps. Ground for the coi l si de of the
rel ay i s suppl i ed on ci rcui t Z1.
When the operator turns the l eft turn si gnal ON,
power fl ows through the coi l i n the rel ay to ground
causi ng the contacts i n the rel ay to swi tch from the
normal l y CLOSED posi ti on to connect ci rcui ts 94 and
L61.
Ci rcui t 94 i s the feed for the contact si de of the
rel ay. Ci rcui t L61 connects from the rel ay to the
trai l er tow connector.
Ci rcui t 94 i s fed power through the normal l y
CLOSED si de of the stop l amp rel ay by ci rcui t F70.
Ci rcui t F70 i s HOT at al l ti mes and protected by a
ci rcui t breaker l ocated i n the ri ght rear quarter
panel .
HELPFUL INFORMATION
Check fuse 11 i n the PDC
Check fuse 8 i n the juncti on bl ock
Check the I n-Li ne ci rcui t breaker
A trai l er brake provi si on i s taped to the harness
at the l ower l eft of the i nstrument panel
TRAILER TOW AFTER-MARKET
The after-market trai l er tow connector i s l ocated i n
the l eft rear quarter panel . The connector contai ns
feed ci rcui t F70 from fuse 8 i n the juncti on bl ock.
Ci rcui t L60 from the ri ght turn si gnal s, ci rcui t L90
for parki ng l amps, and ci rcui t L50 from the stop
l amp swi tch.
8W - 54 - 6 8W - 54 TRAILER TOW ZG
8W-60 POWER WINDOWS
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Page
Body Control Modul e . . . . . . . . . . . . . . . . 8W-60-2, 3
Ci rcui t Breaker 2 . . . . . . . . . . . . . . . . . . 8W-60-2, 3
Dri ver Door Modul e . . . . . . . . . . . . . . . . . 8W-60-2, 4
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3, 4
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2
G305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-4
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
Left Front Power Wi ndow Motor . . . . . . . . . 8W-60-2
Left Rear Power Wi ndow Motor . . . . . . . . . 8W-60-4
Left Rear Power Wi ndow Swi tch . . . . . . . . . 8W-60-4
Passenger Door Modul e . . . . . . . . . . . . . . 8W-60-3, 4
Ri ght Front Power Wi ndow Motor . . . . . . . . 8W-60-3
Component Page
Ri ght Rear Power Wi ndow Motor . . . . . . . . 8W-60-4
Ri ght Rear Power Wi ndow Swi tch . . . . . . . . 8W-60-4
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-4
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-4
ZG 8W - 60 POWER WINDOWS 8W - 60 - 1
12 C1
7
C1
Z1
12
BK
Z1
12
BK
Z1
12
BK
S324
Z1
12
BK
1 C334
G302
2 1
2 DOWN
1 UP
MODULE
DOOR
DRIVER
2
C1 C1
1
M
Q11
16
LB
Q21
16
WT
LEFT
FRONT
POWER
WINDOW
MOTOR
C1
8 9
C1
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
1
13
S204
S306
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
S307
S203
12 C334
2 C302
C1 19 20 C1
BODY
CONTROL
MODULE
GROUP
POWER
OPTION
FULL
F18
12
TN
3 C334
F18
10
TN
C14
7
30A
2
BREAKER
CIRCUIT
BLOCK
JUNCTION
CCD
BUS
(+) (-)
BUS
CCD
CCD
BUS
(+) (-)
BUS
CCD
BATT A250
1 2
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
(8W-10-10)
(8W-12-2)
(8W-12-7)
(8W-45-2)
(8W-30-18)
(8W-30-31)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-30-19)
(8W-30-32)
(8W-15-12)
(8W-15-12)
8W - 60 - 2 8W-60 POWER WINDOWS ZG-RHD
J978W-3 ZGR06001
12 C1
7
Z1
12
BK
Z1
12
BK
Z1
12
BK
S325
Z1
12
BK
1 C351
G301
2 1
2 DOWN
1 UP
MODULE
DOOR
PASSENGER
2 1
M
Q12
16
BR
Q22
16
VT
RIGHT
FRONT
POWER
WINDOW
MOTOR
8 9
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
1
13
S204
S306
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
S307
S203
12 C351
2 C302
C1 19 20 C1
BODY
CONTROL
MODULE
GROUP
POWER
OPTION
FULL
F81
12
TN
3 C351
F81
12
TN
C14
9
30A
2
BREAKER
CIRCUIT
BLOCK
JUNCTION
CCD
BUS
(+)
CCD
(-)
BUS
CCD
BUS
(+) (-)
BUS
CCD
BATT A250
1 2
C1 C1 C1 C1 C1
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
(8W-10-10)
(8W-12-2)
(8W-12-7)
(8W-45-2)
(8W-30-18)
(8W-30-31)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-30-19)
(8W-30-32)
(8W-15-14)
(8W-15-14)
ZG-RHD 8W-60 POWER WINDOWS 8W - 60 - 3
ZGR06002 J978W-3
1 2
LEFT
REAR
POWER
WINDOW
MOTOR
Q22
16
VT
4
5 2
BR
16
Q12
M
1 3
Q28
16
DG/WT
Q27
14
RD/BK
Q27
16
RD/BK
1 C309 2 C343 E
7 5 4 C334
Q17
16
DB/WT
Q17
14
DB/WT
Q18
16
GY/BK
E21
18
OR
E21
18
OR/RD
E20
20
OR/DG
C1
4 3
C1 C1
10
DRIVER
DOOR
MODULE
LEFT
REAR
WINDOW
DRIVER
(DOWN) (UP)
DRIVER
WINDOW
REAR
LEFT LEFT
REAR
DOOR
SWITCH
ILLUMINATION
6
1 UP
2 DOWN
LEFT
REAR
POWER
WINDOW
SWITCH
1 2
Z1
16
BK
Z1
16
BK
Z1
12
BK
G305
S304
D C343 C345 D
S333
G301
BK
12
Z1
BK
16
Z1
BK
16
Z1
2 1
SWITCH
WINDOW
POWER
REAR
RIGHT
2 DOWN
1 UP
6
ILLUMINATION
SWITCH
DOOR
REAR
RIGHT RIGHT
REAR
WINDOW
DRIVER
(UP) (DOWN)
DRIVER
WINDOW
REAR
RIGHT
MODULE
DOOR
PASSENGER
10
C1 C1
3 4
C1
OR/DG
20
E20
OR/DB
18
E20
OR/DB
18
E20
GY/BK
16
Q18
GY/BK
14
Q18
GY/BK
16
Q18
C351 4 5 7
E C345 2 C330 1
DG/WT
16
Q28
DG/WT
14
Q28
DG/WT
16
Q28
3 1
M
Q12
16
BR
2 5
4
VT
16
Q22
MOTOR
WINDOW
POWER
REAR
RIGHT
2 1
(8W-15-14)
(8W-15-14) (8W-15-15)
(8W-15-15)
8W - 60 - 4 8W-60 POWER WINDOWS ZG-RHD
J978W-3 ZGR06003
8W-60 POWER WINDOWS
INDEX
page page
DESCRIPTION AND OPERATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 5
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION AND OPERATION
INTRODUCTION
Al l four power wi ndows can be control l ed by the
swi tches on the Dri vers Door Modul e (DDM). Addi -
ti onal l y, the l eft rear wi ndow as wel l as the ri ght
front and ri ght rear wi ndows have separate swi tches.
The swi tch pod on the DDM a contai ns l ock out
swi tch. The l ock-out feature prevents the wi ndows
from bei ng operated by any swi tch other than the
dri vers door swi tch.
Each rear wi ndow swi tch contai ns an LED. The
DDM prevents i l l umi nati on of the LEDs when the
operator sel ects the wi ndow l ock-out feature.
POWER WINDOWS
Ci rcui t A250 from fuse 11 i n the Power Di stri bu-
ti on Center (PDC) powers ci rcui t F81 through the ci r-
cui t breaker i n cavi ty 2 of the juncti on bl ock. Ci rcui t
F81 suppl i es power to the Dri vers Door Modul e
(DDM) and the Passengers Door Modul e (PDM). The
DDM and PDM operate the power wi ndows. Ci rcui t
Z1 provi des ground for the power wi ndow system.
LEFT FRONT WINDOW OPERATION
The Dri vers Door Modul e operates the l eft front
wi ndow. When the operator sel ects wi ndow DOWN
operati on, the DDM connects ci rcui t F81 to ci rcui t
Q21. Ci rcui t Q21 goes from the swi tch to the power
wi ndow motor. Ground for the motor i s suppl i ed on
the Q11 ci rcui t back to the swi tch. The DDM con-
nects ci rcui t Q11 to ground ci rcui t Z1.
For wi ndow UP operati on the ci rcui ts are reversed.
The DDM connects ci rcui t Q11 to ci rcui t F81 and
connects ci rcui t Q21 to ground ci rcui t Z1.
RIGHT FRONT WINDOW OPERATION
The Passengers Door Modul e (PDM) operates the
ri ght front wi ndow. I f the DRI VER operates the pas-
senger wi ndow, the Dri vers Door Modul e si gnal s the
Passengers Door Modul e over the CCD Bus.
For wi ndow DOWN operati on, the PDM connects
ci rcui t F81 to ci rcui t Q22. Ci rcui t Q22 goes from the
power wi ndow swi tch ci rcui try i n the PDM to the
power wi ndow motor. Ground for the motor i s sup-
pl i ed on ci rcui t Q12 back to the swi tch. The DDM
connects ci rcui t Q12 to ground ci rcui t Z1.
For wi ndow UP operati on the ci rcui ts are reversed.
The PDM connects ci rcui t Q12 to ci rcui t F81 and
connects ci rcui t Q22 to ground ci rcui t Z1.
LEFT REAR WINDOW
Ci rcui ts Q17 and Q27 connect the Dri vers Door
Modul e (DDM) to the l eft rear wi ndow swi tch. When
the operator has not sel ected the wi ndow l ock-out
feature, the DDM connects ci rcui ts Q17 and Q27 to
battery vol tage. At the l eft door harness, ci rcui t Q17
connects to ci rcui t Q18 and ci rcui t Q27 connects to
ci rcui t Q28. Ci rcui ts Q18 and Q28 connect to the l eft
rear power wi ndow swi tch.
I f the wi ndow i s operated from l eft rear swi tch for
wi ndow DOWN operati on, the swi tch connects ci rcui t
Q12 from the power wi ndow motor to ground on ci r-
cui t Z1. The l eft rear wi ndow swi tch connects ci rcui t
Q28 to ci rcui t Q22. Ci rcui t Q22 powers the wi ndow
motor. Ci rcui ts Q12 and Z1 provi de ground.
For wi ndow UP operati on the ci rcui ts are reversed.
The l eft rear wi ndow swi tch connects Q22 to ground
on ci rcui t Z1. Ci rcui t Q18 powers the rear wi ndow
motor. Ci rcui ts Q22 and Z1 provi de ground.
The l eft rear wi ndow swi tch contai ns a Li ght Emi t-
ti ng Di ode (LED). The DDM i l l umi nates the LED on
ci rcui t E21. Ci rcui t E21 connects to ci rcui t E20 at
the l eft door harness. Ci rcui t E20 connects to the l eft
rear wi ndow swi tch and powers the LED.
I f the operator has sel ected the wi ndow l ock-out
feature, the DDM wi l l not suppl y power to the l eft
rear wi ndow swi tch on ci rcui ts Q27 and Q17. Al so,
the DDM does not i l l umi nate the LED i n the swi tch.
I f the wi ndow i s operated from DRI VERS swi tch
for wi ndow DOWN operati on, the DDM powers ci r-
cui t Q27 and grounds ci rcui t Q17. Ci rcui t Q27 con-
nects to ci rcui t Q28 at the l eft rear door harness.
From ci rcui t Q28, current passes through the cl osed
contacts i n the l eft rear wi ndow swi tch to ci rcui t
Q22. Ci rcui t Q22 powers the wi ndow motor. The
ground path for the motor i s on ci rcui t Q12 from the
motor, through the cl osed contacts i n the l eft rear
wi ndow swi tch to ci rcui t Q18, to Q17 back to the
DDM.
ZG 8W - 60 POWER WINDOWS 8W - 60 - 5
For wi ndow UP operati on the ci rcui ts are reversed.
The DDM powers ci rcui t Q17 and grounds ci rcui t
Q27.
RIGHT REAR WINDOW
Ci rcui ts Q18 and Q28 connect the Passengers Door
Modul e (PDM) to the ri ght rear wi ndow swi tch.
When the operator has not sel ected the wi ndow l ock-
out feature, the PDM connects ci rcui ts Q18 and Q28
to battery vol tage.
I f the wi ndow i s operated from ri ght rear swi tch
for wi ndow DOWN operati on, the swi tch connects ci r-
cui t Q12 from the power wi ndow motor to ground on
ci rcui t Z1. The ri ght rear wi ndow swi tch connects ci r-
cui t Q28 to ci rcui t Q22. Ci rcui t Q22 powers the wi n-
dow motor. Ci rcui ts Q12 and Z1 provi de ground.
For wi ndow UP operati on the ci rcui ts are reversed.
The ri ght rear wi ndow swi tch connects Q22 to
ground on ci rcui t Z1. Ci rcui t Q18 from the PDM pow-
ers ci rcui t Q12 through the cl osed contacts i n the
ri ght rear wi ndow swi tch. Ci rcui t Q12 powers the
wi ndow motor. Ci rcui ts Q22 and Z1 provi de ground.
The ri ght rear wi ndow swi tch contai ns a Li ght
Emi tti ng Di ode (LED). The PDM i l l umi nates the
LED on ci rcui t E20.
I f the operator has sel ected the wi ndow l ock-out
feature, the Dri vers Door Modul e si gnal s the PDM
on the CCD bus. I n response, the PDM wi l l not sup-
pl y power to the ri ght rear wi ndow swi tch on ci rcui ts
Q18 and Q28. Al so, the PDM does not i l l umi nate the
LED i n the swi tch.
I f the wi ndow i s operated from DRI VERS swi tch
for wi ndow DOWN operati on, the DDM si gnal s the
PDM over the CCD Bus. I n response, the PDM pow-
ers ci rcui t Q28 and grounds ci rcui t Q18. From ci rcui t
Q28, current passes through the cl osed contacts i n
the ri ght rear wi ndow swi tch to ci rcui t Q22. Ci rcui t
Q22 powers the wi ndow motor. The ground path for
the motor i s on ci rcui t Q12 from the motor, through
the cl osed contacts i n the ri ght rear wi ndow swi tch to
the PDM on ci rcui t Q18.
For wi ndow UP operati on the ci rcui ts are reversed.
After the DDM si gnal s the PDM on the CCD Bus,
the PDM powers ci rcui t Q18 and grounds ci rcui t
Q28.
8W - 60 - 6 8W - 60 POWER WINDOWS ZG
DESCRIPTION AND OPERATION (Continued)
8W-61 POWER DOOR LOCKS
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Page
Body Control Modul e . . . . . . . . . . . . . . . . 8W-61-2, 3
Ci rcui t Breaker 2 . . . . . . . . . . . . . . . . . . 8W-61-2, 3
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . 8W-61-2
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . 8W-61-2, 3, 5
Left Front Door Lock Motor . . . . . . . . . . . . 8W-61-2
Left Rear Door Lock Motor . . . . . . . . . . . . . 8W-61-4
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . . 8W-61-4
Li ftgl ass Li mi t Swi tch . . . . . . . . . . . . . . . . . 8W-61-5
Li ftgl ass Push Button . . . . . . . . . . . . . . . . . 8W-61-5
Li ftgl ass Rel ease Sol enoi d . . . . . . . . . . . . . . 8W-61-5
Passenger Door Modul e . . . . . . . . . . . . . . . . 8W-61-3
Ri ght Front Door Lock Motor . . . . . . . . . . . 8W-61-4
Component Page
Ri ght Rear Door Lock Motor . . . . . . . . . . . . 8W-61-4
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3
S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3
S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
ZG 8W - 61 POWER DOOR LOCKS 8W - 61 - 1
30A
BREAKER
CIRCUIT
Z1
12
BK
Z1
12
BK
Z1
12
BK
S324
F81
10
TN
F81
12
TN
DRIVER
DOOR
MODULE
1 UNLOCK
2 LOCK
Z1
12
BK
Z1
12
BK
G302
1 C334
D1
18
VT/BR
D1
18
VT/BR
D2
18
WT/BK
13
D1
18
VT/BR
D2
18
WT/BK
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
D1
18
VT/BR
1 2
C302
C334
BODY
CONTROL
MODULE
S204 S203
1 2
P34
18
PK/BK
P35
18
OR/VT
5
C1
6
C1
7
C1
9
C1
8
C1
3 C334
12 C1
7 C14
S306 S307
BLOCK
JUNCTION
CCD
BUS
(+) (-)
BUS
CCD
CCD
BUS
(+) (+)
BUS
CCD
1 2
FULL
OPTION GROUP
POWER
19 C1 20 C1
BATT A250
D2
18
WT/BK
MOTOR
LEFT
FRONT
DOOR
LOCK
M
2
PAIR
TWISTED
12
TWISTED
PAIR
PAIR
TWISTED
(8W-10-10)
(8W-12-2)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-45-2)
(8W-15-12)
(8W-15-12)
(8W-12-7)
8W - 61 - 2 8W-61 POWER DOOR LOCKS ZG-RHD
J978W-3 ZGR06101
C14
9
BATT A250
30A
2
BREAKER
CIRCUIT
C351 3
TN
12
F81
TN
12
F81
12
7 6 5 8 9
A
(8W-61-4)
B
(8W-61-4)
TO
S326
TO
S327
P2
18
BK/WT
P34
18
PK/BK
Z1
12
BK
FULL
OPTION GROUP
POWER
Z1
12
BK
Z1
12
BK
Z1
12
BK
S324
Z1
12
BK
Z1
12
BK
G301
1 C351
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
C1 19 20 C1
S203 S204
1 2 C302
S307 S306
13 12 C351
2 UNLOCK
1 LOCK
MODULE
DOOR
PASSENGER
BODY
CONTROL
MODULE
1 2
CCD
BUS
(+) (-)
BUS
CCD
CCD
BUS
(+) (-)
BUS
CCD
JUNCTION
BLOCK
C1 C1 C1 C1 C1
C1
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
(8W-10-10)
(8W-12-2)
(8W-45-2)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-15-14)
(8W-15-12)
(8W-12-7)
ZG-RHD 8W-61 POWER DOOR LOCKS 8W - 61 - 3
ZGR06102 J978W-3
A
(8W-61-3)
B
(8W-61-3)
P2
18
BK/WT
P34
18
PK/BK
FROM
MODULE
DOOR
PASSENGER PASSENGER
DOOR
MODULE
FROM
1 2
M
P2
14
BK/WT
P34
14
PK/BK
P2
14
BK/WT
P2
14
BK/WT
P2
14
BK/WT
P2
16
BK/WT
P34
14
PK/BK
P34
14
PK/BK
P34
14
PK/BK
P34
16
PK/BK
1 2
M
S310 S308
P34
14
PK/BK
P34
18
PK/BK
P2
16
BK/WT
P2
18
BK/WT
3
C323 C C345 3 C330
3
C326
9 C351 10 C351
B A
M
1 2
M
LIFTGATE
LOCK
MOTOR
P2
16
BK/WT
P2
18
BK/WT
P34
14
PK/BK
P34
18
PK/BK
C343 C C309 3
S326 S327
MOTOR
RIGHT
FRONT
DOOR
LOCK
LOCK
DOOR
REAR
RIGHT
MOTOR
MOTOR
LEFT
REAR
DOOR
LOCK
1 1
8W - 61 - 4 8W-61 POWER DOOR LOCKS ZG-RHD
J978W-3 ZGR06103
8
FUSE
20A
8
BATT A250
F70
14
PK/BK
F70
14
PK/BK
F70
16
PK/BK
F70
16
PK/BK
P101
16
OR/PK
P100
14
OR/BR
Z1
14
BK
S336
S315
2 C323
A
B
1
2
2
1
Z1
12
BK
Z1
12
BK
Z1
12
BK
G301
S328
S316
2
C325
JUNCTION
BLOCK
SOLENOID
RELEASE
LIFTGLASS
LIFTGLASS
SWITCH
LIMIT
BUTTON
LIFTGLASS
PUSH
3
7
8 C14
(8W-12-2)
(8W-10-10)
(8W-15-11)
(8W-15-10)
(8W-45-11)
(8W-15-14)
(8W-12-8)
(8W-12-8)
(8W-12-8)
ZG-RHD 8W-61 POWER DOOR LOCKS 8W - 61 - 5
ZGR06104 J978W-3
8W-61 POWER DOOR LOCKS
DESCRIPTION AND OPERATION
INTRODUCTION
The Dri vers Door Modul e (DDM) powers the dri v-
ers door l ock motor. The Passengers Door Modul e
(PDM) powers the passenger, both rear doorl ock and
the l i ftgate l ock motors. The DDM and PDM each
contai n a door l ock swi tch. When one of the swi tches
i s acti vated, a si gnal i s sent on the CCD Bus to the
other door modul e (PDM or DDM dependi ng on
whi ch swi tch acti vated) to ei ther LOCK or UNLOCK
the l ock motors. The Remote Keyl ess Entry transmi t-
ter can al so LOCK or UNLOCK the door l ock and
l i ftgate l ock motors. The PDM contai ns the radi o fre-
quency recei ver that recei ves the RKE transmi tter
si gnal s.
The vehi cl e i s equi pped wi th a Rol l i ng Door Lock
feature. When thi s feature i s enabl ed, the PDM wi l l
l ock the doors and l i ftgate after the vehi cl es reaches
approxi matel y 15 MPH.
POWER DOOR LOCKS
Ci rcui t A250 from fuse 11 i n the Power Di stri bu-
ti on Center (PDC) powers ci rcui t F81 through the ci r-
cui t breaker i n cavi ty 2 of the juncti on bl ock. Ci rcui t
F81 suppl i es power to the Dri vers Door Modul e
(DDM) and the Passengers Door Modul e (PDM). The
DDM and PDM operate the power door l ocks. Ci rcui t
Z1 provi des ground for the power door l ocks.
The PDM contai ns the radi o frequency recei ver
that recei ves the radi o frequency si gnal s from the
Remote Keyl ess Entry (RKE) transmi tter. After
ei ther the passenger door l ock swi tch acti vates or i t
recei ves i nput from the RKE transmi tter, the PDM
sends the appropri ate si gnal to the DDM over the
CCD Bus. When the DRI VERS door l ock swi tch acti -
vates, the DDM sends the appropri ate si gnal to the
PDM.
After recei vi ng a LOCK si gnal , the DDM suppl i es
battery vol tage to the l eft front door l ock motor on
ci rcui t P36. The DDM al so connects ci rcui t P34 from
the motor to ground.
When the DDM recei ves the UNLOCK si gnal , i t
powers ci rcui t P34 and grounds ci rcui t P36.
After recei vi ng a LOCK si gnal , the PDM suppl i es
battery vol tage to the ri ght front door l ock motor,
rear door l ock motors and l i ftgate l ock motors on ci r-
cui t P2. The PDM al so connects ci rcui t P34 from the
motor to ground.
When the DDM recei ves the UNLOCK si gnal , i t
powers ci rcui t P34 and grounds ci rcui t P2.
REMOTE KEYLESS ENTRY
The Remote Keyl ess Entry (RKE) transmi tter
sends three uni que si gnal s to the radi o frequency
recei ver i n Passengers Door Modul e (PDM): LOCK,
UNLOCK and PANI C. After i t recei ves any one of
the three si gnal s, the PDM broadcasts the appropri -
ate si gnal over the CCD bus.
LIFTGLASS
Ci rcui t A250 from fuse 11 i n the Power Di stri bu-
ti on Center (PDC) powers ci rcui t F70 through fuse 8
i n the juncti on bl ock. I f the l i ftgl ass l i mi t swi tch i s
cl osed, i t connects ci rcui t F70 to the l i ftgl ass swi tch
(push button) on ci rcui t P101. When cl osed, the l i ft-
gl ass swi tch connects ci rcui t P101 to ci rcui t P100.
Ci rcui t P100 feeds the l i ftgl ass sol enoi d. Ci rcui t Z1
grounds the sol enoi d.
8W - 61 - 6 8W - 61 POWER DOOR LOCKS ZG
8W-62 POWER MIRRORS
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Page
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . 8W-62-4
Body Control Modul e . . . . . . . . . . . . . . . . 8W-62-2, 3
Ci rcui t Breaker 2 . . . . . . . . . . . . . . . . . . 8W-62-2, 3
Dri ver Door Modul e . . . . . . . . . . . . . . . . . 8W-62-2, 4
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . . 8W-62-4
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
Passenger Door Modul e . . . . . . . . . . . . . . 8W-62-3, 5
Component Page
Passenger Power Mi rror . . . . . . . . . . . . . . . 8W-62-5
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3
ZG 8W - 62 POWER MIRRORS 8W - 62 - 1
8
12
GROUND
9 7
MODULE
DOOR
DRIVER
F81
12
TN
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
1 2 C302
13 C334
19 20
CCD
BUS
(+) (-)
BUS
CCD BODY
CONTROL
MODULE
Z1
12
BK
Z1
12
BK
Z1
12
BK
S306 S307
S203 S204
Z1
12
BK
Z1
12
BK
1 C334
G302
FUSED
B (+)
CCD
BUS
(+) (-)
BUS
CCD
C1 C1 C1
C1
C1 C1
BATT A250
BLOCK
JUNCTION
30A
2
BREAKER
CIRCUIT
7
F81
10
TN
3 C334
C14
FULL
OPTION
POWER
GROUP
S324
12
(8W-15-12)
(8W-10-10)
(8W-12-7)
(8W-12-2)
(8W-15-12)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-45-2)
8W - 62 - 2 8W-62 POWER MIRRORS ZG-RHD
J978W-3 ZGR06201
8
12
GROUND
9 7
MODULE
DOOR
PASSENGER
F81
12
TN
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
D2
18
WT/BK
1 2 C302
13 12 C351
19 20
CCD
BUS
(+) (-)
BUS
CCD BODY
CONTROL
MODULE
Z1
12
BK
Z1
12
BK
Z1
12
BK
S306 S307
S203 S204
Z1
12
BK
Z1
12
BK
1 C351
G301
FUSED
B (+)
CCD
BUS
(+) (-)
BUS
CCD
BATT A250
BLOCK
JUNCTION
30A
2
BREAKER
CIRCUIT
9
F81
12
TN
3 C351
C14
C1
C1 C1 C1
FULL
OPTION
POWER
GROUP
S325
C1 C1
(8W-15-14)
(8W-10-10)
(8W-12-7)
(8W-12-2)
(8W-15-14)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
(8W-45-2)
ZG-RHD 8W-62 POWER MIRRORS 8W - 62 - 3
ZGR06202 J978W-3
A
MODULE
DOOR
DRIVER
DRIVER
POWER
MIRROR
4 5
M M
G H E D C B F
HORIZONTAL
POSITION
SENSOR
SIGNAL
VERTICAL
DRIVER DRIVER
COMMON HORIZONTAL
DRIVER
SENSOR
GROUND
VERTICAL
POSITION
SENSOR
SIGNAL
HEATER
SWITCHED
GROUND SUPPLY
12V
HEATER
F75
20
YL
F73
20
DB
F71
20
WT
F85
20
GN
F86
20
GY
F84
20
VT
Z1
20
BK
C16
20
BK
P114
20
YL/BK
P114
20
YL/BK
P114
18
YL/BK
P114
20
YL/BK
P114
20
BK/YL
4
8
9
A B C353
11 C334
7 C302
3 C231
P112
20
BK/WT
P112
20
YL/WT
P112
18
YL/WT
P112
20
YL/WT
P112
20
YL/WT
C2
AUTO
DAY
NIGHT
MIRROR
(-) (+)
MIRROR
NIGHT
DAY
AUTO
AUTO
DAY
NIGHT
MIRROR
(-) (+)
MIRROR
NIGHT
DAY
AUTO
MIRROR
NIGHT
DAY/
AUTOMATIC
C2 C2 C2 C2 C2 C2 C2
(8W-44-6)
(8W-44-7)
8W - 62 - 4 8W-62 POWER MIRRORS ZG-RHD
J978W-3 ZGR06203
A
MODULE
DOOR
PASSENGER
PASSENGER
POWER
MIRROR
M M
G H E D C B F
HORIZONTAL
POSITION
SENSOR
SIGNAL
VERTICAL
DRIVER DRIVER
COMMON HORIZONTAL
DRIVER
SENSOR
GROUND
VERTICAL
POSITION
SENSOR
SIGNAL
HEATER
SWITCHED
GROUND SUPPLY
12V
HEATER
F75
20
WT
F73
20
DB
F71
20
YL
F85
20
VT
F86
20
GY
F84
20
GN
Z1
20
BK
C16
20
BK
C2 C2 C2 C2 C2 C2 C2 C2
ZG-RHD 8W-62 POWER MIRRORS 8W - 62 - 5
ZGR06204 J978W-3
8W-62 POWER MIRRORS
DESCRIPTION AND OPERATION
INTRODUCTION
The Dri vers Door Modul e (DDM) control s both
power mi rrors. The DDM adjusts the l eft mi rror and
si gnal s the Passenger Door Modul e (PDM) over the
CCD bus to adjust the ri ght mi rror. A push button
swi tch on the outsi de of the DDM control s the hori -
zontal and verti cal posi ti on of both mi rrors. The
DDM al so has a sel ector swi tch wi th ri ght, l eft and
center (off) posi ti ons for mi rror sel ecti on.
Some model s wi th Remote Keyl ess Entry (RKE)
have a memory feature that al l ows the RKE trans-
mi tter to move the dri vers seat and outsi de mi rrors
to a saved posi ti ons. The memory feature al so can set
the radi o push buttons to preset stati ons.
POWER MIRROR
The ci rcui ts from the l eft outsi de mi rror to the
Dri ver Door Modul e (DDM) and ri ght mi rror to Pas-
senger Door Modul e have i denti cal ci rcui t numbers.
Each mi rror has two motors; an UP/DOWN motor
and a LEFT/RI GHT motor. The motors swi tch pol ar-
i ty to al l ow mi rror adjustment. The DDM and PDM
adjust mi rror posi ti on by suppl yi ng power or ground
to the mi rror motors.
Each mi rror has a verti cal posi ti on sensor and a
hori zontal posi ti on sensor. The sensors i n the l eft
mi rror connect to the DDM. Sensors i n the ri ght mi r-
ror connect to the PDM. The DDM and PDM deter-
mi ne hori zontal posi ti on on ci rcui t F85 and verti cal
posi ti on on ci rcui t F84. Ci rcui t F86 provi des ground
for each sensor.
I f the vehi cl e i s equi pped wi th an automati c day/
ni ght rear vi ew mi rror, the l eft power mi rror al so
automati cal l y adjusts to varyi ng ambi ent l i ght i nten-
si ty. Ci rcui ts P114 and P112 connect the l eft power
mi rror to the automati c day/ni ght rear vi ew mi rror.
LEFT MIRROR ADJ USTMENT
The DDM adjusts the posi ti on of the l eft mi rror.
When an UP adjustment i s made, the DDM suppl i es
power to the l eft mi rror UP/DOWN motor on ci rcui t
F71 and grounds ci rcui t F73.
When a DOWN adjustment i s made, the pol ari ty
reveres. The DDM suppl i es power to ci rcui t F73 and
grounds ci rcui t F71.
Duri ng LEFT adjustments, the DDM suppl i es
power to the LEFT/RI GHT motor on ci rcui t F75 and
grounds ci rcui t F73.
For RI GHT adjustments, the pol ari ty reverses. The
DDM suppl i es power to ci rcui t F73 and grounds ci r-
cui t F75.
RIGHT MIRROR ADJ USTMENT
The PDM adjusts the ri ght mi rror i n response to
si gnal s i t recei ves over the CCD bus from the DDM.
When an UP adjustment i s made, the PDM suppl i es
power to the ri ght mi rror UP/DOWN motor on ci rcui t
F71 and grounds ci rcui t F73.
When a DOWN adjustment i s made, the pol ari ty
reveres. The PDM suppl i es power to ci rcui t F73 and
grounds ci rcui t F71.
Duri ng LEFT adjustments, the PDM suppl i es
power to the LEFT/RI GHT motor on ci rcui t F75 and
grounds ci rcui t F73.
For RI GHT adjustments, the pol ari ty reverses. The
PDM suppl i es power to ci rcui t F73 and grounds ci r-
cui t F75.
HEATER ELEMENTS
The Dri ver Door Modul e (DDM) powers the heater
ci rcui t i n the l eft power mi rror. The Passenger Door
Modul e powers the heater el ement i n the ri ght mi r-
ror. When the Body Control Modul e (BCM) detects
the operator pressed the rear wi ndow defogger
swi tch, i t broadcasts the appropri ate message to the
DDM and PDM over the CCD bus. The DDM and
PDM acti vate the heater el ements i n the mi rrors
unti l the BCM no l onger broadcasts the message on
the CCD bus.
The DDM and PDM power the heater el ement on
ci rcui t C16. On ci rcui t Z1, the DDM and PDM pro-
vi de ground for the heater el ements.
8W - 62 - 6 8W - 62 POWER MIRRORS ZG
8W-63 POWER SEAT
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Component Page
Ci rcui t Breaker 3 . . . . 8W-63-2, 3, 4, 8, 9, 10, 13, 14
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . 8W-63-15
Dri ver Heated Seat Back . . . . . . . . . . . . . . 8W-63-11
Dri ver Heated Seat Cushi on . . . . . . . . . . . 8W-63-11
Dri ver Lumbar Motor . . . . . . . . . . . . . . . . . 8W-63-3
Dri ver Lumbar Sensor/Motor . . . . . . . . . 8W-63-5, 6
Dri ver Lumbar Swi tch . . . . . . . . . . . . . . 8W-63-2, 3
Dri ver Power Seat Front Ri ser Motor . . 8W-63-7, 10
Dri ver Power Seat Front Ri ser
Motor Sensor . . . . . . . . . . . . . . . . . . . . 8W-63-6, 7
Dri ver Power Seat Hori zontal Motor . . . 8W-63-6, 10
Dri ver Power Seat Hori zontal
Motor Sensor . . . . . . . . . . . . . . . . . . . . . . 8W-63-6
Dri ver Power Seat Rear Ri ser Motor . . . 8W-63-7, 10
Dri ver Power Seat Rear Ri ser
Motor Sensor . . . . . . . . . . . . . . . . . . . . 8W-63-6, 7
Dri ver Power Seat Recl i ner Motor . . . . . 8W-63-6, 10
Dri ver Power Seat Recl i ner Motor Sensor . . 8W-63-6
Dri ver Power Seat Swi tch . . . . . . . . . . . 8W-63-8, 10
Dri ver Seat Heater Control Modul e . . . 8W-63-11, 14
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-13, 14
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-13, 14
G305 . . . . . . . . . . . . . . 8W-63-2, 3, 4, 8, 9, 10, 11, 12
Heated Seat Swi tch . . . . . . . . . 8W-63-11, 12, 13, 14
Juncti on Bl ock . . . . . . 8W-63-2, 3, 4, 8, 9, 10, 13, 14
Memory Seat Modul e . . . . . . . 8W-63-2, 5, 6, 7, 8, 15
Memory Set Swi tch 1 Set . . . . . . . . . . . . . 8W-63-15
Passenger Door Modul e . . . . . . . . . . . . . . . 8W-63-15
Component Page
Passenger Heated Seat Back . . . . . . . . . . . 8W-63-12
Passenger Heated Seat Cushi on . . . . . . . . 8W-63-12
Passenger Lumbar Motor . . . . . . . . . . . . . . 8W-63-4
Passenger Lumbar Swi tch . . . . . . . . . . . . . . 8W-63-4
Passenger Power Seat Front Ri ser Motor . . 8W-63-9
Passenger Power Seat Hori zontal Motor . . . 8W-63-9
Passenger Power Seat Rear Ri ser Motor . . . 8W-63-9
Passenger Power Seat Recl i ner Motor . . . . . 8W-63-9
Passenger Power Seat Swi tch . . . . . . . . . . . 8W-63-9
Passenger Seat Heater Control
Modul e . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12, 13
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-13, 14
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-13, 14
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-13, 14
S304 . . . . . . . . . . . . . . 8W-63-2, 3, 4, 8, 9, 10, 11, 12
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-15
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-15
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-13, 14
S333 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4, 9, 12
S400 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5, 6, 7
S401 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5, 6, 7
S402 . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3, 8, 10, 11
S403 . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3, 8, 10, 14
S404 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12, 13
S405 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4, 9, 13
S406 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4, 9, 12
S407 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-11, 14
ZG 8W - 63 POWER SEAT 8W - 63 - 1
20A
3
BREAKER
CIRCUIT
BATT A7
F35
16
RD
F35
14
RD
F35
18
RD
1 C329
S403
3
2 4 1
P104
20
YL/RD
17
Z1
18
BK
Z1
18
BK
S402
Z1
14
BK
Z1
16
BK
G305
Z1
12
BK
S304
2 C329
DRIVER
LUMBAR
SWITCH
1 FILL
2 VENT
C1
8
19
MEMORY
SEAT
MODULE
10
1
Z1
16
BK
Z1
16
BK
F35
16
RD
F35
16
RD
1 2
C1 16
LG/DB
20
P105
5
JUNCTION
BLOCK
12
C2 C2
C2 C2
LUMBAR
FORWARD
SWITCH
SENSE
BACKWARD
SENSE
SWITCH
LUMBAR
B (+)
FUSED
B (+)
FUSED
GROUND GROUND
C13
(8W-10-12)
(8W-12-2)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-12-18)
(8W-12-18)
8W - 63 - 2 8W-63 POWER SEAT ZG-RHD
J978W-3 ZGR06301
12
20A
3
BREAKER
CIRCUIT
BATT A7
F35
16
RD
F35
14
RD
F35
18
RD
1 C329
S403
3
2 4 5 1
P107
18
OR/BK
P106
18
DG/WT
1 2
MOTOR
LUMBAR
DRIVER
Z1
18
BK
Z1
18
BK
S402
Z1
14
BK
Z1
16
BK
G305
Z1
12
BK
S304
2 C329
DRIVER
LUMBAR
SWITCH
1 FILL
2 VENT
1 2
JUNCTION
BLOCK
C13
M
(8W-12-2)
(8W-10-12)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-12-18)
(8W-12-18)
ZG-RHD 8W-63 POWER SEAT 8W - 63 - 3
ZGR06302 J978W-3
20A
3
BREAKER
CIRCUIT
BATT A7
F35
16
RD
F35
14
RD
F35
18
RD
1 C335
S405
3
2 4 5 1
P107
18
OR/BK
P106
18
DG/WT
1 2
MOTOR
LUMBAR
PASSENGER
Z1
18
BK
Z1
18
BK
S406
Z1
14
BK
Z1
16
BK
G305
Z1
12
BK
S333
2 C335
PASSENGER
LUMBAR
SWITCH
1 FILL
2 VENT
S304
Z1
10
BK
1 2
JUNCTION
BLOCK
12
M
C13
(8W-10-12)
(8W-12-2)
(8W-15-15)
(8W-15-14)
(8W-15-15)
(8W-15-13)
(8W-12-18)
(8W-12-18)
8W - 63 - 4 8W-63 POWER SEAT ZG-RHD
J978W-3 ZGR06303
C1
1 9
C2 C2
20
2 1 5
MEMORY
SEAT
MODULE
DRIVER
LUMBAR
SENSOR/
MOTOR
P106
16
DG/WT
P107
16
OR/BK
P29
20
BR/WT
P29
20
BR/WT
S401
M
6V
SENSOR
SUPPLY
LUMBAR
VENT
DRIVER DRIVER
FILL
LUMBAR
3 4
20
DB/WT
P103
BR/RD
P28
20
20
S400
BR/RD
P28
7
C1
LUMBAR
SENSOR
POSITION
2
C1
GROUND
SENSOR
(8W-70-4) (8W-63-6)
ZG-RHD 8W-63 POWER SEAT 8W - 63 - 5
ZGR06304 J978W-3
A
SENSOR
DRIVER
POWER
SEAT
HORIZONTAL
MOTOR
B C
MOTOR
RECLINER
SEAT
POWER
DRIVER
SENSOR
P29
20
BR/WT
P29
20
BR/WT
P29
20
BR/WT
C B
A
S400
P28
20
BR/RD
P28
20
BR/RD
P28
20
BR/RD
P47
20
LB
P25
20
VT/RD
C1
1
S401
MEMORY
SEAT
MODULE
C2
2
C1 3 2 C1 C1 6
7
C2 C2
6 3
C2
B A 2 1
P115
16
GY/LG
P117
16
RD/BR
P41
16
GY/WT
P43
16
GY/LB
MEMORY
SEAT
MODULE
DRIVER
POWER
SEAT
HORIZONTAL
MOTOR MOTOR
RECLINER
SEAT
POWER
DRIVER
BR/WT
20
P29
5
BR/WT
20
P29
C
BR/WT
20
P29
SENSOR
MOTOR
RISER
FRONT
SEAT
POWER
DRIVER DRIVER
POWER
SEAT
REAR
RISER
MOTOR
SENSOR
MOTOR
SENSOR/
LUMBAR
DRIVER
M M
6V
SENSOR
SUPPLY
RECLINER
DRIVER
RECLINER
DRIVER
HORIZONTAL
POSITION
SENSE
SENSOR
GROUND
RECLINER
POSITION
SENSE
MOTOR MOTOR
C
MOTOR MOTOR
DRIVER DRIVER
HORIZONTAL HORIZONTAL
(8W-63-5)
(8W-63-7) (8W-63-7)
(8W-63-5)
(8W-70-4)
8W - 63 - 6 8W-63 POWER SEAT ZG-RHD
J978W-3 ZGR06305
C
MOTOR
DRIVER
POWER
SEAT
REAR
RISER
B A
P29
20
BR/WT
P29
20
BR/WT
P29
20
BR/WT
A B
C
S400
P28
20
BR/RD
P28
20
BR/RD
P28
20
BR/RD
P26
20
BR
P27
20
LB/RD
C1
1
S401
MEMORY
SEAT
MODULE
C2
11
C1 5 2 C1 C1 4
17
C2 C2
18 12
C2
2 1 2 1
P113
16
RD/BK
P111
16
YL/DB
P121
16
RD/GY
P119
16
YL/RD
MEMORY
SEAT
MODULE
DRIVER
POWER
SEAT
REAR
RISER
SENSOR SENSOR
RISER
FRONT
SEAT
POWER
DRIVER
MOTOR
MOTOR MOTOR
RISER
FRONT
SEAT
POWER
DRIVER
REAR
RISER
POSITION
SENSE
GROUND
SENSOR
SENSE
POSITION
RISER
FRONT
REAR
RISER
DOWN
DRIVER DRIVER
UP
RISER
REAR FRONT
RISER
DOWN
DRIVER DRIVER
UP
RISER
FRONT
M M
6V
SENSOR
SUPPLY
(8W-63-5)
(8W-63-6)
(8W-70-4)
ZG-RHD 8W-63 POWER SEAT 8W - 63 - 7
ZGR06306 J978W-3
20A
3
BREAKER
CIRCUIT
F35
16
RD
F35
14
RD
F35
16
RD
S403
1 C329
3 UP
2 FWD
1 BACK
SWITCH
SEAT
POWER
DRIVER
10
5
7 9 8 6 3 4 2 1
P21
18
RD/LG
P19
18
YL/LG
P13
18
RD/WT
P11
18
YL/WT
P15
18
YL/LB
P17
18
RD/LB
P48
18
GY/WT
P40
18
GY/LB
4 3 4 3 2 1 4 3
8 9 10 11 12 13 15 14
MEMORY
SEAT
MODULE
BATT A7
Z1
16
BK
Z1
14
BK
Z1
16
BK
Z1
16
BK
S304
G305
S402
2 C329
FRONT
RISER
DOWN
SWITCH
SENSE SENSE
SWITCH
UP
RISER
FRONT
SENSE
SWITCH
DOWN
RISER
REAR
SENSE
SWITCH
UP
RISER
REAR
SENSE
SWITCH
FORWARD
HORIZONTAL
SENSE
SWITCH
DOWN
RECLINER
SENSE
SWITCH
UP
RECLINER HORIZONTAL
REARWARD
SWITCH
SENSE
JUNCTION
BLOCK
4 DOWN
12
C1 C1 C1 C1 C1 C1 C1 C1
C13
(8W-10-12)
(8W-12-2)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-12-18)
(8W-12-18)
8W - 63 - 8 8W-63 POWER SEAT ZG-RHD
J978W-3 ZGR06307
20A
3
BREAKER
CIRCUIT
F35
16
RD
F35
14
RD
F35
16
RD
S405
1 C335
10
3 UP
2 FWD
1 BACK
SWITCH
SEAT
POWER
PASSENGER
7
5
10 8 9 6 3 4 2 1
P20
16
RD/LG
P18
16
YL/LG
P12
16
RD/WT
P10
16
YL/WT
P14
16
YL/LB
P16
16
RD/LB
P42
16
GY/WT
P44
16
GY/LB
4 3 4 3 2 1 4 3
BATT A7
Z1
18
BK
Z1
14
BK
Z1
10
BK
Z1
12
BK
S304
G305
S406
2 C329
MOTOR
PASSENGER
POWER
SEAT
FRONT
RISER
2 1
RISER
REAR
SEAT
POWER
PASSENGER
MOTOR
2 1
1 2
PASSENGER
POWER
SEAT
HORIZONTAL
MOTOR
MOTOR
RECLINER
SEAT
POWER
PASSENGER
B A
M
M
M
M
S333
Z1
16
BK
JUNCTION
BLOCK
4 DOWN
C14
(8W-10-12)
(8W-12-2)
(8W-15-14)
(8W-15-13)
(8W-15-15)
(8W-15-15)
(8W-12-18)
(8W-12-18)
ZG-RHD 8W-63 POWER SEAT 8W - 63 - 9
ZGR06308 J978W-3
20A
3
BREAKER
CIRCUIT
F35
16
RD
F35
14
RD
F35
16
RD
S403
1 C335
10
5
7 9 8 6 3 4 2 1
P21
16
RD/LG
P19
16
YL/LG
P13
16
RD/WT
P11
16
YL/WT
P15
16
YL/LB
P17
16
RD/LB
P41
16
GY/WT
P43
16
GY/LB
4 3 4 3 2 1 4 3
BATT A7
Z1
16
BK
Z1
14
BK
Z1
12
BK
S304
G305
S402
2 C329
MOTOR
DRIVER
POWER
SEAT
FRONT
RISER
2 1
RISER
REAR
SEAT
POWER
DRIVER
MOTOR
2 1
1 2
DRIVER
POWER
SEAT
HORIZONTAL
MOTOR
MOTOR
RECLINER
SEAT
POWER
DRIVER
B A
M
M
M
M
Z1
16
BK
JUNCTION
BLOCK
4 DOWN
2 FWD
3 UP
DRIVER
POWER
SEAT
SWITCH
1 BACK
10 C13
(8W-10-12)
(8W-12-2)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-12-18)
(8W-12-18)
8W - 63 - 10 8W-63 POWER SEAT ZG-RHD
J978W-3 ZGR06309
8
DRIVER
HEATED
SEAT
SWITCH
OUTPUT DRIVER
SEAT
HEATED
3
GROUND
7
MODULE
CONTROL
HEATER
SEAT
DRIVER
C A
B
P87
16
BK/OR
P7
18
LB/BK
P7
18
LB/BK
Z1
16
BK
Z1
14
BK
Z1
16
BK
Z1
12
BK
S407
S402
2 C329
S304
G305
CUSHION
SEAT
HEATED
DRIVER
DRIVER
HEATED
SEAT
BACK
1
P7
18
LB/BK
P7
18
LB/BK
P7
20
LB
5 C329
3 C301
HEATED
SEAT
SWITCH
A
D
BK
Z1
16
BK
Z1
20
B
P88
16
BR/BK
(8W-63-14)
(8W-15-15)
(8W-15-15)
(8W-15-15)
ZG-RHD 8W-63 POWER SEAT
HEATED SEAT
8W - 63 - 11
ZGR06310 J978W-3
8 3 7
MODULE
CONTROL
HEATER
SEAT
PASSENGER
C A
B
P87
16
BK/OR
P8
18
LB/WT
P8
18
LB/WT
Z1
18
BK
Z1
14
BK
Z1
10
BK
Z1
12
BK
S404
S406
2 C335
S304
G305
CUSHION
SEAT
HEATED
PASSENGER
PASSENGER
HEATED
SEAT
BACK
4
P8
18
LB/WT
P8
20
LB/WT
3 C335
4 C301
HEATED
SEAT
SWITCH
A
D
BK
Z1
16
BK
Z1
20
B
P88
16
BR/BK
PASSENGER
HEATED
SEAT
SWITCH
OUTPUT
HEATED
SEAT
DRIVER GROUND
16
Z1
BK
S333
(8W-15-14)
(8W-63-13)
(8W-15-15)
(8W-15-15)
(8W-15-13)
8W - 63 - 12 8W-63 POWER SEAT
HEATED SEAT
ZG-RHD
J978W-3 ZGR06311
12
FUSE
10A
20A
3
BREAKER
CIRCUIT
12
BATT A7 RUN A22
2
1
2
0
4
5
2
1 8
F35
16
RD
F35
16
RD
F35
14
RD
F71
20
PK/DG
F71
20
PK/DG
F71
18
PK/DG
F71
18
PK/DG
F87
18
WT/BK
F71
20
PK/DG
4 C302
1 4 3 C335
S218
S317
P8
20
LB/WT
P8
18
LB/WT
MODULE
CONTROL
HEATER
SEAT
PASSENGER
P8
18
LB/WT
P8
18
LB/WT
S404
4 C301
G304
Z1
20
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
S202
S216
2 C301
S405
SWITCH POD)
(PART OF
SWITCH
SEAT
HEATED
FUSED
B (+)
FUSED
IGN
(RUN)
OUTPUT
SWITCH
SEAT
HEATED
PASSENGER
JUNCTION
BLOCK
9
C9 C13
1 HIGH
2 LOW
0 OFF
(8W-12-2)
(8W-10-8) (8W-10-12)
(8W-12-18)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-63-12)
(8W-12-10)
(8W-12-10)
(8W-12-18)
(8W-12-10)
ZG-RHD 8W-63 POWER SEAT
HEATED SEAT
8W - 63 - 13
ZGR06312 J978W-3
12
FUSE
10A
9
20A
3
BREAKER
CIRCUIT
12
BATT A7 RUN A22
2
1
2
0
1
5
2
1 8
F35
16
RD
F35
16
RD
F35
14
RD
F71
20
PK/DG
F71
20
PK/DG
F71
18
PK/DG
F71
18
PK/DG
F87
18
PK/DG
F71
20
PK/DG
4 C302
1 6 5 C329
S218
S317
P7
20
LB
P7
18
LB/BK
MODULE
CONTROL
HEATER
SEAT
DRIVER
P7
18
LB/BK
P7
18
LB/BK
S407
3 C301
G304
Z1
20
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
S202
S216
2 C301
S403
SWITCH POD)
(PART OF
SWITCH
SEAT
HEATED
FUSED
B (+)
FUSED
IGN
(RUN)
DRIVER
HEATED
SEAT
JUNCTION
BLOCK
C9 C13
1 HIGH
0 OFF
2 LOW
(8W-10-12)
(8W-12-2)
(8W-10-8)
(8W-12-18)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-63-11)
(8W-12-10)
(8W-12-10)
(8W-12-18)
(8W-12-10)
8W - 63 - 14 8W-63 POWER SEAT
HEATED SEAT
ZG-RHD
J978W-3 ZGR06313
D C B A
M1
20
GY
G49
20
OR
P22
20
BR
Z1
20
BK
1 2 3
3 MEM 2
MEMORY
SET
SWITCH
1 SET
2 MEM 1
19
C1
18
C1
D1
20
VT/BR
D2
20
WT/BK
3 4
D1
18
VT/BR
D2
18
WT/BK
S306 S307
D1
18
VT/BR
D2
18
WT/BK
D2
18
WT/BK
D1
18
VT/BR
13 12
C351
8 9
D1
18
VT/BR
D1
18
VT/BR
13 C334
D2
18
WT/BK
D2
18
WT/BK
12 C334
SWITCHED
MUX
LED
SUPPLY
5V
SUPPLY GROUND
CCD
BUS
(-)
CCD
BUS
(+)
BUS
CCD
(+) (-)
BUS
CCD
CCD
BUS
(-) (+)
CCD
BUS
MEMORY
SEAT
MODULE
8 9
C329
DRIVER
DOOR
MODULE
MODULE
DOOR
PASSENGER
C1 C1
C3 C3 C3 C3
C1 C1
SET
LED
DRIVER
(8W-60-3)
(8W-61-3)
(8W-62-3)
(8W-30-18)
(8W-30-31)
(8W-30-19)
(8W-30-32)
ZG-RHD 8W-63 POWER SEAT
MEMORY SEAT
8W - 63 - 15
ZGR06314 J978W-3
8W-63 POWER SEAT
INDEX
page page
DESCRIPTION AND OPERATION
HEATED SEATS . . . . . . . . . . . . . . . . . . . . . . . . 17
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 16
MEMORY SEATS . . . . . . . . . . . . . . . . . . . . . . . 17
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION AND OPERATION
INTRODUCTION
Both front power seats on thi s vehi cl e have sepa-
rate motors for adjusti ng l umbar, front, rear, hori zon-
tal and verti cal posi ti on. Al so, the vehi cl e may have
opti onal heated seats.
Some model s wi th Remote Keyl ess Entry (RKE)
have a memory feature that al l ows the RKE trans-
mi tter to move the dri vers seat and outsi de mi rrors
to saved posi ti ons. The memory feature al so can set
the radi o push buttons to preset stati ons.
POWER SEATS
Both power seat system are protected by a 20 amp
ci rcui t breaker l ocated i n cavi ty 3 of the juncti on
bl ock. Ci rcui t A7 from fuse 15 i n Power Di stri buti on
Center (PDC) powers ci rcui t F35 through the ci rcui t
breaker.
I n both power seats, ci rcui t F35 feeds the seat
posi ti on swi tch and l umbar adjustment swi tch. A
BUS bar i nternal to the swi tches feeds al l the con-
tacts. Ci rcui t Z1 provi des ground for each power seat.
LUMBAR ADJ USTMENT
Lumbar posi ti on i s adjustabl e on both power seats.
Ci rcui t F35 feeds the l eft and ri ght l umbar adjust-
ment swi tch. I denti cal ci rcui ts from each swi tch
power or ground the l umbar motor to adjust l umbar
posi ti on.
On ei ther power seat, duri ng LUMBAR FORWARD
adjustments, the l umbar swi tch connects ci rcui t F35
to ci rcui t P106. Ci rcui t P106 feeds the l umbar motor.
The ground path i s suppl i ed on ci rcui t P107 from the
motor through the cl osed contacts i n swi tch to ci rcui t
Z1.
For LUMBAR AFT adjustments, the ci rcui ts are
reversed. Pl 07 powers the motor and ci rcui t P106
provi des ground.
DRIVERS SEAT
When the operator sel ects the HORI ZONTAL FOR-
WARD functi on, the swi tch passes power from ci rcui t
F35 to ci rcui t P15. Ci rcui t P15 connects to the motor.
Ground i s provi ded on ci rcui t P17 ci rcui t back to the
swi tch. A bus bar i nternal to the swi tch connects ci r-
cui t P17 to ground on ci rcui t Z1.
For HORI ZONTAL REARWARD functi on the ci r-
cui ts are reversed. P17 i s the feed, and P15 i s the
ground.
When the operator sel ects the REAR VERTI CAL
UP functi on, the swi tch passes power from ci rcui t
F35 to ci rcui t P11. Ci rcui t P11 connects to the motor.
Ground i s provi ded on ci rcui t P13 back to the swi tch.
A bus bar i nternal to the swi tch connects ci rcui t P13
to ground on ci rcui t Z1.
For REAR VERTI CAL DOWN functi on the ci rcui ts
are reversed. P13 i s the feed, and P11 i s the ground.
When the operator sel ects the FRONT VERTI CAL
UP functi on, the swi tch passes power from ci rcui t
F35 to ci rcui t P19. Ci rcui t P19 connects to the motor.
Ground i s provi ded on ci rcui t P21 back to the swi tch.
A bus bar i nternal to the swi tch connects ci rcui t P21
to ground on ci rcui t Z1.
For FRONT VERTI CAL DOWN functi on the ci r-
cui ts are reversed. P21 i s the feed, and P19 i s the
ground.
When the operator sel ects the RECLI NE UP func-
ti on, the swi tch passes power from ci rcui t F35 to the
P43 ci rcui t. Ci rcui t P43 connects to the motor.
Ground i s provi ded on ci rcui t P41 back to the swi tch.
A bus bar i nternal to the swi tch connects ci rcui t P41
to ground on ci rcui t Z1.
For RECLI NE DOWN functi on the ci rcui ts are
reversed. P41 i s the feed, and P43 i s the ground.
PASSENGERS SEAT
When the operator sel ects the HORI ZONTAL FOR-
WARD functi on, the swi tch passes power from ci rcui t
F35 to ci rcui t P14. Ci rcui t P14 connects to the motor.
Ground i s provi ded on ci rcui t P16 ci rcui t back to the
swi tch. A bus bar i nternal to the swi tch connects ci r-
cui t P16 to ground on ci rcui t Z1.
For HORI ZONTAL REARWARD functi on the ci r-
cui ts are reversed. P16 i s the feed, and P14 i s the
ground.
When the operator sel ects the REAR VERTI CAL
UP functi on, the swi tch passes power from ci rcui t
F35 to ci rcui t P10. Ci rcui t P10 connects to the motor.
Ground i s provi ded on ci rcui t P12 back to the swi tch.
8W - 63 - 16 8W - 63 POWER SEAT ZG
A bus bar i nternal to the swi tch connects ci rcui t P12
to ground on ci rcui t Z1.
For REAR VERTI CAL DOWN functi on the ci rcui ts
are reversed. P12 i s the feed, and P10 i s the ground.
When the operator sel ects the FRONT VERTI CAL
UP functi on, the swi tch passes power from ci rcui t
F35 to ci rcui t P18. Ci rcui t P18 connects to the motor.
Ground i s provi ded on ci rcui t P20 back to the swi tch.
A bus bar i nternal to the swi tch connects ci rcui t P20
to ground on ci rcui t Z1.
For FRONT VERTI CAL DOWN functi on the ci r-
cui ts are reversed. P20 i s the feed, and P18 i s the
ground.
When the operator sel ects the RECLI NE UP func-
ti on, the swi tch passes power from ci rcui t F35 to the
P44 ci rcui t. Ci rcui t P44 connects to the motor.
Ground i s provi ded on ci rcui t P42 back to the swi tch.
A bus bar i nternal to the swi tch connects ci rcui t P42
to ground on ci rcui t Z1.
For RECLI NE DOWN functi on the ci rcui ts are
reversed. P42 i s the feed, and P44 i s the ground.
MEMORY SEATS
Ci rcui t A7 from fuse 15 i n the Power Di stri buti on
Center (PDC) powers ci rcui t F35 through the ci rcui t
breaker i n cavi ty 3 of the juncti on bl ock. Ci rcui t F35
powers the Memory Seat Modul e (MSM). Ci rcui t Z1
provi des ground for the MSM.
When the operator moves the power seat swi tch or
the l umbar adjustment swi tch, contacts i n the swi tch
CLOSE connecti ng the swi tch to the MSM. The MSM
recei ves thi s i nput and operates the proper seat
motor.
The dri vers memory seat system can be acti vated
by ei ther one of the memory swi tches on the l eft door
panel or through the Remote Keyl ess Entry (RKE)
transmi tter. I f one of the memory swi tches on the
door panel i s pushed, the Dri vers Door Modul e
(DDM) si gnal s the MSM on the CCD bus. I f the
memory functi on i s acti vated by the RKE transmi t-
ter, the Passenger Door Modul e (PDM) si gnal s the
MSM on the CCD bus.
The fol l owi ng i s a l i st of the ci rcui ts that connect
from the power seat swi tch to the MSM and thei r
functi ons:
P40 - Recl i ner up
P48 - Recl i ner down
P19 - Front up
P21 - Front down
P11 - Rear up
P13 - Rear down
P15 - Seat forward
P17 - Seat rearward
P104 l umbar rearward
P105 l umbar forward
To operate the seat motor(s), the control modul e
suppl i es the power and ground. The fol l owi ng i s a l i st
of the ci rcui ts that connect from the control modul e
to the seat motors:
P119, P121 - Seat front up and down
P111, P113 - Rear up and down
P115, P117 - Seat forward and rearward
P41, P43 - Recl i ner forward and rearward
P106, P107 Lumbar forward and rearward
SEAT POSITION SENSORS
The Memory Seat Modul e (MSM) recei ves seat
posi ti on i nputs from fi ve sensors i n the dri vers seat.
On ci rcui t P29, the MSM suppl i es power to the seat
posi ti on sensors on ci rcui t P29. The MSM provi des
ground for the sensors on ci rcui t P28.
Ci rcui t P25 provi des the i nput from the hori zontal
forward/rearward motor sensor to the MSM. Ci rcui t
P47 provi des the i nput from the recl i ne motor sensor.
Ci rcui t P103 sends the l umbar motor sensor i nput.
Ci rcui t P27 provi des the i nput from the rear ri ser
motor sensor to the MSM. Ci rcui t P26 provi des the
i nput from the front ri ser motor sensor. Ci rcui t P29
from the MSM powers the ri ser motor sensors. The
MSM provi des ground for the ri ser motor sensors on
ci rcui t P28.
MEMORY SWITCH
The memory swi tch i s used for programmi ng the
desi red seat posi ti ons i nto the MSM memory. The
memory swi tch al so programs power mi rror posi ti on
i nto the Dri vers Door Modul e (DDM) and the Passen-
gers Door Modul e (PDM), and presets radi o stati on
sel ecti ons.
Ci rcui t P22 from DDM suppl i es power to the three
sets of swi tches i n the memory swi tch; set, memory
1, and memory 2. The three swi tch sets are wi red i n
paral l el and each contai ns a separate resi stor. The
vol tage l evel present on ci rcui t P22 depends on whi ch
memory swi tch i s acti vated. Ci rcui t Z1 from the
DDM provi des ground for the swi tches.
After a memory swi tch acti vates, the DDM broad-
casts the appropri ate si gnal on CCD bus. The MSM
adjusts seat posi ti on i n response to the si gnal .
Ci rcui t M1 from the DDM powers the green Li ght
Emi tti ng Di odes (LED) i n the set swi tch. Ci rcui t G49
powers the red LED i n the set swi tch. Ci rcui t Z1 pro-
vi des ground for the LEDs.
HEATED SEATS
Separate control modul es operate the dri ver and
passenger heated seats. Ci rcui t F35 from the ci rcui t
breaker i n cavi ty 3 of the juncti on bl ock suppl i es
power to both heated seat control modul es. Ci rcui t
A7 from fuse 15 i n the Power Di stri buti on Center
(PDC) powers ci rcui t F35 through the ci rcui t breaker.
ZG 8W - 63 POWER SEAT 8W - 63 - 17
DESCRIPTION AND OPERATION (Continued)
When the i gni ti on swi tch i s i n the RUN posi ti on, i t
connects ci rcui t A1 from fuse 8 i n the PDC to ci rcui t
A22. Ci rcui t A22 powers ci rcui t F71 through fuse 12
i n the juncti on bl ock. Ci rcui t F71 spl i ces to suppl y
power to the dri ver and passenger heated seat
swi tches and provi des an i nput to the heated seat
control modul es. Ci rcui t Z1 provi des ground for the
control modul es and both heated seat swi tches.
Both heated seat swi tches have three posi ti ons;
OFF, LOW or HI GH. Ci rcui t P7 sends the dri verss
heated seat swi tch si gnal to the dri vers heated seat
control modul e. Ci rcui t P8 sends the passenger
heated seat swi tch si gnal to the passenger heated
seat control modul e. I n the LOW and HI GH posi -
ti ons, the dri vers heated seat swi tch connects battery
vol tage on ci rcui t F71 to ci rcui t P7 (dri vers) or P8
(passenger). The LOW and HI GH posi ti on detentes
have a resi stor i n seri es between the detente and ci r-
cui t P7 or P8. I nternal to the swi tch, vol tage from
ci rcui t F71 passes through the resi stor to ci rcui t P7
or P8. The vol tage l evel on ci rcui t P7 or P8 from the
swi tch depends on swi tch posi ti on (LOW or HI GH).
After recei vi ng a si gnal from i ts heated seat
swi tch, the heated seat control modul es powers the
heater gri ds i n the seat. From ei ther control modul e,
ci rcui t P87 powers the gri d i n the dri vers seat cush-
i on Current fl ows out of the seat cushi on on ci rcui t
P88 to the gri d on the seat back. Ci rcui t Z1 from the
gri d i n the seat back suppl i es ground.
Each heated seat control modul e moni tors seat
temperature through a thermi stor i n each seat.
When seat temperature reaches the temperature
sel ected by the operator through the heated seat
swi tch, the control modul e stops suppl yi ng vol tage to
the heated seat gri ds. To mai ntai n sel ected seat tem-
perature, the control modul e cycl es the gri d ON and
OFF.
8W - 63 - 18 8W - 63 POWER SEAT ZG
DESCRIPTION AND OPERATION (Continued)
8W-64 POWER SUNROOF
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Page
Ci rcui t Breaker 1 . . . . . . . . . . . . . . . . . . . . 8W-64-2
El ectroni c Fl asher . . . . . . . . . . . . . . . . . . . . 8W-64-2
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
Component Page
S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
Sl i di ng Roof Motor . . . . . . . . . . . . . . . . . . . 8W-64-3
Sl i di ng Roof Posi ti on Swi tch . . . . . . . . . . . . 8W-64-3
Sunroof Control Modul e . . . . . . . . . . . . . 8W-64-2, 3
Sunroof Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-64-2
ZG 8W - 64 POWER SUNROOF 8W - 64 - 1
13
FUSE
15A
RUN-ACC A31 BATT A7
20A
1
BREAKER
CIRCUIT
FLASHER
ELECTRONIC
4 2 7
Z1
18
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
2 C301
S322 S216
S220
S202
G304
Z1
16
BK
Z1
16
BK
Z1
16
BK
F86
16
LG/BK
F86
16
LG/BK
F86
16
LG/BK
F86
16
LG/BK
1 4 C371
5 C231
5 1
3
2 CLOSE
1 OPEN
SWITCH
SUNROOF
1 2
F86
16
LG/BK
Q42
16
LB
S320
3 2 C371
Q42
16
WT
Q41
16
WT
Q41
16
LB
MODULE
CONTROL
SUNROOF
FUSED
B (+)
GROUND
GROUND
JUNCTION
BLOCK
5
C5
1
C15 C4
FUSED
IGN.
(RUN-ACC)
SUNROOF
SWITCH
OUTPUT
(CLOSED) (OPEN)
OUTPUT
SWITCH
SUNROOF
1 4 3 2
(8W-10-9)
(8W-12-2)
(8W-10-12)
(8W-12-5)
(8W-15-18)
(8W-15-18)
(8W-15-17)
(8W-15-17) (8W-15-16)
(8W-52-2)
(8W-52-6)
(8W-12-4)
(8W-12-11)
8W - 64 - 2 8W-64 POWER SUNROOF ZG-RHD
J978W-3 ZGR06401
M
SWITCH
POSITION
ROOF
SLIDING
MOTOR
ROOF
SLIDING
SLIDING
ROOF
POSITION
SWITCH
OUTPUT OUTPUT
SWITCH
POSITION
ROOF
SLIDING SLIDING
ROOF
POSITION
SWITCH
OUTPUT
DRIVER
MOTOR
ROOF
SLIDING SLIDING
ROOF
MOTOR
DRIVER
MODULE
CONTROL
SUNROOF
18
WT
18
GN
18
BR
18
BK
18
GN
ZG-RHD 8W-64 POWER SUNROOF 8W - 64 - 3
ZGR06402 J978W-3
8W-64 POWER SUNROOF
INDEX
page
DESCRIPTION AND OPERATION
POWER SUNROOF . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
POWER SUNROOF
When the i gni ti on swi tch i s i n the ACCESSORY or
RUN posi ti on i t connects ci rcui t A1 from fuse 8 i n
the Power Di stri buti on Center (PDC) to ci rcui t A31.
Ci rcui t A31 powers ci rcui t F86 through the ci rcui t
breaker i n cavi ty 1 of the juncti on bl ock. Ci rcui t F86
feeds the power sunroof control modul e and swi tch.
Ci rcui t Z1 provi des ground for the sunroof system.
When the operator sel ects the OPEN functi on, vol t-
age i s provi ded on ci rcui t F86 through the cl osed con-
tacts i n the swi tch to ci rcui t Q41. Ci rcui t Q41
connects between the swi tch and the control modul e.
The control modul e then acti vates the motor and
moves the sunroof to the desi red posi ti on. A posi ti on
sensor i s used to prevent the sunroof from bei ng
moved to far i n any one di recti on. When the sensor
detects the roof i s at the end of i ts travel i t sends a
si gnal to the control modul e and vol tage i s shut off to
the motor.
When the operator sel ects the CLOSE functi on,
vol tage i s provi ded on ci rcui t F86 through the cl osed
contacts i n the swi tch to ci rcui t Q42. Ci rcui t Q42
connects between the swi tch and the control modul e.
The control modul e then acti vates the motor and
moves the sunroof to the desi red posi ti on. The posi -
ti on sensor detects when the roof i s at the end of i ts
travel i t sends a si gnal to the control modul e and
vol tage i s shut off to the motor.
8W - 64 - 4 8W - 64 POWER SUNROOF ZG
8W-65 SPEED PROPORTIONAL STEERING
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Page
Data Li nk Connector . . . . . . . . . . . . . . . . . . 8W-65-2
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-2
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-65-2
S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3
S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3
S3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3
S4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3
S98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3
S99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-2
Component Page
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-2
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-2
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-2
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-2
Speed Proporti onal Steeri ng Control
Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-65-3
Speed Proporti onal Steeri ng Modul e . . . . . . 8W-65-2
Speed Proporti onal Steeri ng Sol enoi d . . . . . 8W-65-3
Steeri ng Wheel Speed Sensor . . . . . . . . . . . 8W-65-3
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . 8W-65-2
ZG 8W - 65 SPEED PROPORTIONAL STEERING 8W - 65 - 1
1
6
FUSE
15A
JUNCTION
BLOCK
C8
RUN A22
F83
18
YL/DG
F83
18
YL/DG
S212
G18
C235
F83
18
YL/DG
S119
F83
20
YL/DG
10
8
FUSED
IGN.
(RUN)
12 13
S200
F14 C234
D83
20
BK/PK
D83
18
BK/PK
D83
20
BK/PK
7
DATA
LINK
CONNECTOR
12
6
C235
D98
20
WT
D98
20
WT
SCI
TRANSMIT
SCI
RECEIVE
6
5 C132
G7
18
WT/OR
G7
18
WT/OR
S131
G7
18
WT/OR
3
VEHICLE
SPEED
SENSOR
VEHICLE
SPEED
SENSOR
SIGNAL
S121
Z2
20
BK
Z2
12
BK
G109
GROUND
G12
4
MODULE
STEERING
PROPORTIONAL
SPEED
(8W-10-8)
(8W-15-5)
(8W-15-5)
(8W-33-3)
(8W-70-2)
(8W-30-2)
(8W-30-2) (8W-12-6)
(8W-12-6)
(8W-12-2)
(8W-12-6)
8W - 65 - 2 8W-65 SPEED PROPORTIONAL STEERING
GAS ENGINES
ZG-RHD
J978W-3 ZGR06501
A
SENSOR
SPEED
WHEEL
STEERING
B C D
18 17 16 15
C235
12 13 14 15
3 5 14 9
5V
SUPPLY
GROUND SIGNAL A SIGNAL B
SPEED
PROPORTIONAL
STEERING
CONTROL
MODULE
SIGNAL B SIGNAL A GROUND SUPPLY
5V
S1
20
BK/YL
S1
20
BK/YL
S2
20
BK/LG
S2
20
BK/LG
S3
20
PK/WT
S3
20
PK/WT
S4
20
VT
S4
20
VT
2
SOLENOID
STEERING
PROPORTIONAL
SPEED
1 2
CONTROL
LOW
CONTROL
HIGH
HIGH
CONTROL
LOW
CONTROL
1
S99
18
LG
S98
18
LB
ZG-RHD 8W-65 SPEED PROPORTIONAL STEERING
GAS ENGINES
8W - 65 - 3
ZGR06502 J978W-3
8W-65 SPEED PROPORTIONAL STEERING
INDEX
page page
DESCRIPTION AND OPERATION
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . 4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPEED PROPORTIONAL STEERING CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPEED PROPORTIONAL STEERING
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
INTRODUCTION
The speed proporti oni ng steeri ng system automati -
cal l y adjusts steeri ng effort based on vehi cl e speed.
The system provi des addi ti onal steeri ng assi st whi l e
the vehi cl e i s stati onary or at l ow dri vi ng speeds. At
sl ower speeds, the system provi des greater assi st. At
hi gher speeds, i t provi des l ess assi st resul ti ng i n
i ncreased steeri ng effort.
I n the RUN posi ti on, the i gni ti on swi tch connects
ci rcui t A1 from fuse 8 i n the Power Di stri buti on Cen-
ter (PDC) to ci rcui t A22. Ci rcui t A22 powers ci rcui t
F83 through fuse 6 i n the juncti on bl ock. Ci rcui t F83
suppl i es power to the Speed Proporti onal Steeri ng
Control Modul e (SPSCM). Ci rcui t Z2 provi des ground
for the SPSCM.
SPEED PROPORTIONAL STEERING CONTROL
MODULE
Ci rcui t F83 powers the Speed Proporti onal Steer-
i ng Control Modul e (SPSCM). Ci rcui t Z2 provi des
ground for the SPSCM.
On ci rcui t S1, the SPSCM suppl i es 5 vol ts to the
steeri ng wheel speed sensor. The sensor provi des two
si gnal s to the SPSCM on ci rcui ts S3, and S4. The
SPSCM provi des ground for the steeri ng wheel speed
sensor on ci rcui t S2.
Ci rcui t G7 suppl i es the vehi cl e speed sensor to the
SPSCM.
SPEED PROPORTIONAL STEERING SOLENOID
The speed proporti onal steeri ng control modul e
(SPSCM) operates the speed proporti onal steeri ng
sol enoi d. The SPSCM suppl i es a pul se wi dth modu-
l ated vol tage to the sol enoi d. Ci rcui ts S99 and S98
connect the SPSCM to the sol enoi d.
DATA LINK CONNECTOR
Ci rcui ts D98 and D99 connect the Speed Propor-
ti onal Steeri ng Control Modul e (SPSCM) to the data
l i nk connector. Ci rcui t D99 connects to ci rcui t D83
whi ch conti nues to the data l i nk connector. The
SPSCM transmi ts data to the scan tool through the
data l i nk connector on ci rcui t D99. The SPSCM
recei ves data from the scan tool on ci rcui t D98.
8W - 65 - 4 8W - 65 SPEED PROPORTIONAL STEERING ZG
8W-70 SPLICE INFORMATION
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Page
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S102 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16; 8W-70-6, 9
S103 . . . . . . . . . . . . . . . . . . . 8W-12-15; 8W-50-8; 8W-52-8
S104 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7; 8W-52-8
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
S106 . . . . . . . . . . . . . . . . . . . 8W-10-5; 8W-39-6; 8W-41-2
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
S109 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5; 8W-52-8
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6; 8W-70-8
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-4; 8W-53-3
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8; 8W-35-2
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S128 . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 19; 8W-70-7
S129 . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 19; 8W-70-7
S130 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7; 8W-30-22
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-7
S134 . . . . . . . . . . . . . . . . . . . 8W-15-6; 8W-21-4; 8W-50-4
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4, 8
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-4; 8W-20-3
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-24
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-9
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-30
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-25
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
S149 . . . . . . . . . . . . . 8W-15-4; 8W-15-5, 8W-52-3, 8W-52-8
S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
S152 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7; 8W-52-8
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18, 31
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19, 32
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-4; 8W-45-7
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-11
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7; 8W-39-2
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-8
S212 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6; 8W-50-11
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-12
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
S219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 5
Component Page
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 8
S223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8
S224 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6; 8W-42-3
S225 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6; 8W-42-3
S226 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8; 8W-42-4
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S302 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18; 8W-45-2
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9; 8W-50-4
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19, 32
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18, 31
S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S309 . . . . . . . . . . . . . . . . . . . . . . 8W-15-13; 8W-47-9, 10
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
S318 . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8; 8W-47-9, 10
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13
S322 . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21; 8W-15-16
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S328 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10; 8W-45-11
S329 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-14; 8W-45-11
S330 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9; 8W-54-3
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
S332 . . . . . . . . . . . . . . . . . . . 8W-10-4; 8W-12-9; 8W-48-2
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
S400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4
S401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-6
S402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
S404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-12
S405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
S406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
S407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-11
S408 . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17; 8W-52-3, 8
S409 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5; 8W-52-3, 8
S410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
S411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
S413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
S414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
S415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15
S417 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
S418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
S419 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10; 8W-51-6
S420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28
S421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-26
ZG 8W - 70 SPLICE INFORMATION 8W - 70 - 1
3
SENSOR
OXYGEN
HEATED
UPSTREAM
K4
18
BK/LB BK/LB
20
K4
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
1 2
SENSOR
TEMPERATURE
COOLANT
ENGINE
K4
16
BK/LB BK/LB
16
K4
INTAKE
AIR
TEMPERATURE
SENSOR
2
3
TRANSMISSION
SOLENOID
ASSEMBLY
K4
18
BK/LB BK/LB
20
K4
SENSOR
POSITION
THROTTLE
1
K4
18
BK/LB
K4
20
BK/LB
SENSOR
POSITION
CAMSHAFT
2
S135
S127
(4.0L)
S131
3
G7
18
WT/OR WT/OR
18
G7
6
G7
18
WT/OR
MODULE
STEERING
PROPORTIONAL
SPEED
G7
18
WT/OR
5 C132
POWERTRAIN
CONTROL
MODULE
SENSOR
SPEED
VEHICLE
VEHICLE
SPEED
SENSOR
MODULE
CONTROL
POWERTRAIN
K6
18
VT/WT VT/WT
18
K6
1
S132
B27
C2
C2
B31
2
VT/WT
18
K6
TRANSMISSION
SOLENOID
ASSEMBLY
(8W-31-3)
(8W-30-17)
(8W-30-17)
(8W-33-3)
(8W-30-17)
(8W-33-3)
(8W-30-17)
(8W-65-2)
(8W-70-3)
(8W-30-7)
(8W-30-9) (8W-31-3)
(8W-30-9) (8W-30-9) (8W-30-9) (8W-30-14)
8W - 70 - 2 8W-70 SPLICE INFORMATION ZG-RHD
J978W-3 ZGR07001
2
K4
18
BK/LB
BATTERY
TEMPERATURE
SENSOR
S102
K4
20
BK/LB
10 C131
4.0L 5.2L
K4
20
BK/LB
K4
18
BK/LB BK/LB
20
K4
K4
18
BK/LB
ASSEMBLY
SOLENOID
TRANSMISSION
3
(4.0L)
S127
1
OIL
PRESSURE
SENSOR
BK/LB
20
K4 K4
18
BK/LB
MODULE
CONTROL
POWERTRAIN
K4
18
BK/LB
SENSOR
SPEED
VEHICLE
2
A4
C1
3
K4
18
BK/LB
SENSOR
OXYGEN
HEATED
DOWNSTREAM
BK/LB
18
K4
3
(5.2L)
SENSOR
OXYGEN
HEATED
UPSTREAM
2
K4
20
BK/LB BK/LB
18
K4
3 2
K4
20
BK/LB
(4.0L)
SENSOR
POSITION
CRANKSHAFT TRANSMISSION
SOLENOID
ASSEMBLY
(5.2L)
(4.0L)
SENSOR
POSITION
CAMSHAFT
A
(8W-70-4)
S136
(5.2L)
TO
S135
(8W-30-7)
(8W-31-3) (8W-30-7)
(8W-30-13)
(8W-30-13)
(8W-33-3)
(8W-30-2)
(8W-30-3)
(8W-30-7)
(8W-30-8)
(8W-30-13)
(8W-30-16)
(8W-30-10)
(8W-70-2)
(8W-31-3)
(8W-70-6)
(8W-30-16)
ZG-RHD 8W-70 SPLICE INFORMATION
GAS ENGINES
8W - 70 - 3
ZGR07002 J978W-3
K4
20
BK/LB
SENSOR
POSITION
CRANKSHAFT
2
2
K4
16
BK/LB
2
K4
16
BK/LB
SENSOR
TEMPERATURE
AIR
INTAKE
SENSOR
TEMPERATURE
COOLANT
ENGINE
2
CAMSHAFT
POSITION
SENSOR
BK/LB
20
K4
A
(8W-70-3)
FROM
S135
K4
20
BK/LB
SENSOR
POSITION
THROTTLE
3 1
BK/LB
20
K4
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
K4
18
BK/LB
S136
(5.2L)
MEMORY
SEAT
MODULE
BR/RD
20
P28
BR/RD
20
P28
A
P28
20
BR/RD
C
SENSOR
MOTOR
HORIZONTAL
SEAT
POWER
DRIVER DRIVER
POWER
SEAT
RECLINER
MOTOR
SENSOR
C
BR/RD
20
P28
2
C1
SENSOR
MOTOR
RISER
FRONT
SEAT
POWER
DRIVER DRIVER
POWER
SEAT
REAR
RISER
MOTOR
SENSOR
A
P28
20
BR/RD BR/RD
20
P28
3
S400
(MEMORY SEATS)
MOTOR
SENSOR/
LUMBAR
DRIVER
(8W-63-5)
(8W-63-6)
(8W-63-7)
(8W-63-5)
(8W-63-7) (8W-63-7)
(8W-63-6) (8W-63-6)
(8W-30-8)
(8W-30-8)
(8W-31-4)
(8W-30-7)
(8W-30-8) (8W-30-8)
(8W-30-7)
8W - 70 - 4 8W-70 SPLICE INFORMATION ZG-RHD
J978W-3 ZGR07003
DG/WT
20
L87 L87
20
DG/WT
L87
20
DG/WT
LAMP
STOP
MOUNTED
HIGH
CENTER 1 1 1
A C359
L87
18
DG/WT
1
C326
DG/WT
18
L87
C316 8
WT/TN
18
L50
8
L50
18
WT/TN
LAMP
OUTAGE
MODULE
L50
18
WT/TN WT/TN
18
L50
MODULE
OUTAGE
LAMP
WT/TN
18
L50
2
L50
18
WT/TN
L50
18
WT/TN
2 C316
L50
18
WT/TN
L50
18
WT/TN
2 C316
L50
18
WT/TN
C372 1
WT/TN
18
L50
A
CONNECTOR
TOW
TRAILER
AFTERMARKET
1
A
LAMP
OUTAGE
MODULE
7
WT/TN
18
L50
LAMP
STOP
TAIL/
LEFT
L73
18
PK/WT
1 C328
PK/WT
L73
18
7 C316
18
L50
WT/TN
L50
18
WT/TN
WT/TN
18
L50
WT/TN
L50
18
C316
6
18
L74
PK/BK
C320 1
PK/WT
18
L73
RIGHT
TAIL/
STOP
LAMP
L50
18
WT/TN
6
MODULE
OUTAGE
LAMP
A
CONTROLLER
ANTI-LOCK
BRAKE
12
WT/TN
18
L50
16 C304
L50
18
WT/TN
5
L50
18
WT/TN
STOP
LAMP
SWITCH
12
C305
L50
18
WT/TN
S312
NO. 2 NO. 3
CENTER
HIGH
MOUNTED
STOP
LAMP
NO. 1
LAMP
STOP
MOUNTED
HIGH
CENTER
LAMP
OUTAGE
MODULE
TRAILER
TOW
MODULE
OUTAGE
LAMP
TOW
TRAILER
TRAILER
TOW
LAMP
OUTAGE
MODULE
LAMP
OUTAGE
MODULE
TRAILER
TOW
FACTORY AFTERMARKET
C1 C1
8
9
C1 C1
8
TRAILER
STOP
TOW
LAMP
RELAY
GAS DIESEL
L50
18
WT/TN WT/TN
18
L50
S337
20
9 C132
WT/TN
18
L50
CONTROLLER
MSA
GAS DIESEL
(8W-51-5) (8W-51-5)
(8W-33-2)
(8W-35-3)
(8W-51-3)
(8W-51-4)
(8W-51-3)
(8W-54-3)
(8W-54-4)
(8W-51-3) (8W-51-3)
(8W-51-5)
(8W-30-29)
ZG-RHD 8W-70 SPLICE INFORMATION 8W - 70 - 5
ZGR07004 J978W-3
4 2
FUEL
SENDER
UNIT SENSOR
LEVEL
COOLANT
S102
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
15 C304
C4 4
MODULE
CONTROL
POWERTRAIN
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
12 C132
S141
(8W-30-28) (8W-30-29)
(8W-30-28)
(8W-30-29)
(8W-70-9)
8W - 70 - 6 8W-70 SPLICE INFORMATION
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR07005
23 9
MODULE
PUMP
FUEL
10 45 68
CONTROLLER
MSA
1
GENERATOR
C4
57 1 3 B17
SOLENOID
EGR
MODULE
CONTROL
POWERTRAIN
RELAY
PLUG
GLOW AUTOMATIC
SHUT
DOWN
S128
S129
A142
16
DG/OR
A142
14
DG/OR
A142
16
DG/OR
A142
16
DG/OR
A142
14
DG/OR
A142
16
DG/OR
A142
16
DG/OR
A142
16
DG/OR
A142
16
DG/OR
A142
16
DG/OR
A142
14
DG/OR
A142
16
DG/OR
12 C131
RELAY
(8W-30-26)
(8W-30-22)
(8W-20-2)
(8W-30-28)
(8W-30-27) (8W-30-26)
(8W-30-27)
ZG-RHD 8W-70 SPLICE INFORMATION
DIESEL ENGINE
8W - 70 - 7
ZGR07006 J978W-3
B 2
SENSOR
TEMPERATURE
COOLANT
ENGINE MASS
AIR
FLOW
CONTROLLER
MSA
2 8
K4
18
BK/LB
K4
18
BK/LB
S211
PEDAL
POSITION
SENSOR
CLOCKSPRING
K4
18
BK/LB
F8 C234 H13 C236
NO
CONNECTION
K4
18
BK/LB
K4
18
BK/LB
K4
18
BK/LB
K4
20
BK/LB
K4
20
BK/LB
K4
20
BK/LB
K4
20
BK/LB
6 C131
S119
S136
33
MODULE
MODULE
PUMP
FUEL
BK/LB
18
K4
4
(8W-30-29)
(8W-30-29)
(8W-30-23)
(8W-31-6)
(8W-33-3)
(8W-30-26)
(8W-30-26)
8W - 70 - 8 8W-70 SPLICE INFORMATION
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR07007
2 2 4
2 2
COOLANT
LEVEL
SENSOR
SENSOR
SPEED
VEHICLE
SENSOR
FUEL
IN
WATER
MODULE
CONTROL
POWERTRAIN
SENSOR
PRESSURE
OIL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
12 C132 3 C917
S102
S141
C4
(8W-30-29)
(8W-33-5)
(8W-30-24)
(8W-30-24)
(8W-30-28)
(8W-30-29)
(8W-30-29)
ZG-RHD 8W-70 SPLICE INFORMATION
DIESEL ENGINE
8W - 70 - 9
ZGR07008 J978W-3
8W-80 CONNECTOR PIN-OUTS
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component Page
A/C Heater Control - C1 . . . . . . . . . . . . . . . 8W-80-5
A/C Heater Control - C2 . . . . . . . . . . . . . . . 8W-80-5
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . . 8W-80-5
A/C Low Pressure Swi tch . . . . . . . . . . . . . . 8W-80-5
Aftermarket Trai l er Tow Connector . . . . . . . 8W-80-5
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-80-6
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-80-6
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . 8W-80-6
Auto Headl amp Li ght Sensor/VTSS LED . . 8W-80-6
Automati c Day/Ni ght Rearvi ew Mi rror . . . . 8W-80-6
Automati c Temperature Control Modul e . . . 8W-80-7
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-80-7
Battery Temperature Sensor . . . . . . . . . . . . 8W-80-7
Bl end Actuator Door Motor (wi th Automati c
Temperature Control ) . . . . . . . . . . . . . . . 8W-80-8
Bl end Actuator Motor Actuator (wi th Manual A/C-
heater) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8
Bl ower Motor (wi th Manual A/C-heater) . . . 8W-80-8
Bl ower Motor (wi th Automati c
Temperature Control ) . . . . . . . . . . . . . . . 8W-80-8
Bl ower Motor Resi stor Bl ock
(wi th Manual A/C-heater) . . . . . . . . . . . . 8W-80-8
Bl ower Power Modul e . . . . . . . . . . . . . . . . . 8W-80-9
Body Control Modul e - C1 . . . . . . . . . . . . . . 8W-80-9
Body Control Modul e - C2 . . . . . . . . . . . . . 8W-80-10
Body Control Modul e - C3 . . . . . . . . . . . . . 8W-80-11
Brake Warni ng Swi tch . . . . . . . . . . . . . . . 8W-80-11
C102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
C131 (Gas) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C131 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C132 (Gas) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C132 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C141 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
C150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
C159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
C160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
C182 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
C206 (wi th Manual A/C-heater) . . . . . . . . . 8W-80-14
C206 (wi th Automati c Temperature
Control ) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
Component Page
C235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C305 (Gas) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C305 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . . 8W 80-19
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C372 (wi th Factory Trai l er Tow) . . . . . . . . 8W-80-25
C917 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
Camshaft Posi ti on Sensor (Gas) . . . . . . . . 8W-80-26
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
Center Hi gh Mounted Stop Lamp No. 1 . . 8W-80-26
Center Hi gh Mounted Stop Lamp No. 2 . . 8W-80-26
Center Hi gh Mounted Stop Lamp No. 3 . . 8W-80-27
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
Cl utch I nterl ock Swi tch (Di esel ) . . . . . . . . 8W-80-27
Control l er Anti -Lock Brake . . . . . . . . . . . . 8W-80-27
Cool ant Level Sensor (Di esel ) . . . . . . . . . . 8W-80-27
Crankshaft Posi ti on Sensor (Di esel ) . . . . . 8W-80-28
Crankshaft Posi ti on Sensor (Gas) . . . . . . . 8W-80-28
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-80-28
Dayti me Runni ng Lamp Modul e . . . . . . . . 8W-80-29
ZG 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1
Component Page
Dome/Readi ng Lamp . . . . . . . . . . . . . . . . . 8W-80-29
Downstream Heated Oxygen Sensor . . . . . 8W-80-29
Dri ver Door Modul e - C1 . . . . . . . . . . . . . . 8W-80-29
Dri ver Door Modul e - C2 . . . . . . . . . . . . . . 8W-80-29
Dri ver Door Modul e - C3 . . . . . . . . . . . . . . 8W-80-30
Dri ver Heated Seat Back . . . . . . . . . . . . . . 8W-80-30
Dri ver Heated Seat Cushi on . . . . . . . . . . . 8W-80-30
Dri ver Lumbar Motor . . . . . . . . . . . . . . . . 8W-80-30
Dri ver Power Seat Front Ri ser Motor . . . . 8W-80-31
Dri ver Power Seat Front Ri ser
Motor Sensor . . . . . . . . . . . . . . . . . . . . . 8W-80-31
Dri ver Power Seat Hori zontal Motor . . . . . 8W-80-31
Dri ver Power Seat Hori zontal
Motor Sensor . . . . . . . . . . . . . . . . . . . . . 8W-80-31
Dri ver Power Seat Lumbar Sensor/Motor . 8W-80-31
Dri ver Power Seat Lumbar Swi tch . . . . . . 8W-80-32
Dri ver Power Seat Rear Ri ser Motor . . . . . 8W-80-32
Dri ver Power Seat Rear Ri ser
Motor Sensor . . . . . . . . . . . . . . . . . . . . . 8W-80-32
Dri ver Power Seat Recl i ner Motor . . . . . . . 8W-80-32
Dri ver Power Seat Recl i ner Motor Sensor . 8W-80-33
Dri ver Power Seat Swi tch . . . . . . . . . . . . . 8W-80-33
Dri ver Seat Heater Control Modul e . . . . . 8W-80-33
Dri ver Si de Ai rbag . . . . . . . . . . . . . . . . . . 8W-80-34
Duty Cycl e EVAP/Purge Sol enoi d . . . . . . . 8W-80-34
EGR Sol enoi d (Di esel ) . . . . . . . . . . . . . . . . 8W-80-34
Engi ne Cool ant Temperature Sensor
Si gnal (Di esel ) . . . . . . . . . . . . . . . . . . . . 8W-80-34
Engi ne Cool ant Temperature Sensor
(wi th 4.0L Engi ne) . . . . . . . . . . . . . . . . . 8W-80-34
Engi ne Cool ant Temperature Sensor
(wi th 5.2L Engi ne) . . . . . . . . . . . . . . . . . 8W-80-34
Engi ne Starter Motor . . . . . . . . . . . . . . . . 8W-80-35
Evaporati ve System Leak Detecti on
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
Factory Trai l er Tow Connector . . . . . . . . . 8W-80-35
Fl oor Consol e Lamps . . . . . . . . . . . . . . . . . 8W-80-35
Four Wheel Dri ve Swi tch . . . . . . . . . . . . . 8W-80-36
Fuel Heater (Di esel ) . . . . . . . . . . . . . . . . . 8W-80-36
Fuel Pump Modul e (Di esel ) . . . . . . . . . . . . 8W-80-36
Fuel Pump Modul e(Gas) . . . . . . . . . . . . . . 8W-80-36
Fuel Sender Uni t (Di esel ) . . . . . . . . . . . . . 8W-80-36
Fuel Ti mi ng Sol enoi d (Di esel ) . . . . . . . . . . 8W-80-36
G-Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-37
Generator (Gas) . . . . . . . . . . . . . . . . . . . . . 8W-80-37
Generator (Di esel ) . . . . . . . . . . . . . . . . . . . 8W-80-37
Gl ove Box Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-37
Gl ow Pl ug Rel ay (Di esel ) . . . . . . . . . . . . . . 8W-80-37
Graphi c Di spl ay Modul e Or Vehi cl e
I nformati on Center . . . . . . . . . . . . . . . . 8W-80-38
Headl amp Level i ng Swi tch . . . . . . . . . . . . 8W-80-38
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-80-39
Hi gh Speed Bl ower Motor Rel ay . . . . . . . . 8W-80-39
Horn No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-39
Component Page
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-39
I dl e Ai r Control Motor (wi th 4.0L Engi ne) . 8W-80-40
I dl e Ai r Control Motor (wi th 5.2L Engi ne) . 8W-80-40
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-80-40
I n-Car Temperature Sensor . . . . . . . . . . . . 8W-80-40
I njector No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
I njector No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
I njector No. 3 . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
I njector No. 4 . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
I njector No. 5 . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
I njector No. 6 . . . . . . . . . . . . . . . . . . . . . . 8W-80-42
I njector No. 7 (wi th 5.2 L Engi ne) . . . . . . . 8W-80-42
I njector No. 8 (wi th 5.2 L Engi ne) . . . . . . . 8W-80-42
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-80-42
I ntake Ai r Temperature Sensor . . . . . . . . . 8W-80-42
Juncti on Bl ock - C1 . . . . . . . . . . . . . . . . . . 8W-80-42
Juncti on Bl ock - C2 . . . . . . . . . . . . . . . . . . 8W-80-43
Juncti on Bl ock - C3 . . . . . . . . . . . . . . . . . . 8W-80-43
Juncti on Bl ock - C4 . . . . . . . . . . . . . . . . . . 8W-80-43
Juncti on Bl ock - C5 . . . . . . . . . . . . . . . . . . 8W-80-43
Juncti on Bl ock - C6 . . . . . . . . . . . . . . . . . . 8W-80-44
Juncti on Bl ock - C7 . . . . . . . . . . . . . . . . . . 8W-80-44
Juncti on Bl ock - C8 . . . . . . . . . . . . . . . . . . 8W-80-44
Juncti on Bl ock - C9 . . . . . . . . . . . . . . . . . . 8W-80-45
Juncti on Bl ock - C10 . . . . . . . . . . . . . . . . . 8W-80-45
Juncti on Bl ock - C11 . . . . . . . . . . . . . . . . . 8W-80-45
Juncti on Bl ock Body Connector - C13 . . . . 8W-80-45
Juncti on Bl ock Body Connector - C14 . . . . 8W-80-46
Juncti on Bl ock (Overhead Consol e) - C15 . 8W-80-46
Key-I n Swi tch/Hal o Lamp . . . . . . . . . . . . 8W-80-46
Lamp Outage Modul e - C1 . . . . . . . . . . . . 8W-80-47
Lamp Outage Modul e - C2 . . . . . . . . . . . . 8W-80-47
Left Ai rbag Sensor . . . . . . . . . . . . . . . . . . 8W-80-47
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-80-48
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-80-48
Left Door Courtesy Lamp . . . . . . . . . . . . . 8W-80-48
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-80-48
Left Front Cyl i nder Lock Swi tch . . . . . . . . 8W-80-48
Left Front Door Lock Motor . . . . . . . . . . . 8W-80-49
Left Front Door Speaker . . . . . . . . . . . . . . 8W-80-49
Left Front Park Lamp . . . . . . . . . . . . . . . . 8W-80-49
Left Front Power Wi ndow Motor . . . . . . . . 8W-80-49
Left Front Si de Marker Lamp . . . . . . . . . . 8W-80-49
Left Front Turn Si gnal Lamp . . . . . . . . . . 8W-80-50
Left Front Wheel Speed Sensor . . . . . . . . . 8W-80-50
Left Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-80-50
Left Headl amp Level i ng Motor . . . . . . . . . 8W-80-50
Left I nstrument Panel Speaker . . . . . . . . . 8W-80-50
Left Li cense Lamp . . . . . . . . . . . . . . . . . . . 8W-80-51
Left Park Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-51
Left Park turn Si gnal Marker . . . . . . . . . . 8W-80-51
Left Rear Door Lock Motor . . . . . . . . . . . . 8W-80-51
8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS ZG
DESCRIPTION AND OPERATION (Continued)
Component Page
Left Rear Door Speaker . . . . . . . . . . . . . . . 8W-80-51
Left Rear Fog Lamp . . . . . . . . . . . . . . . . . 8W-80-51
Left Rear Power Wi ndow Motor . . . . . . . . 8W-80-52
Left Rear Power Wi ndow Swi tch . . . . . . . . 8W-80-52
Left Rear Si de Marker Lamp . . . . . . . . . . 8W-80-52
Left Rear Turn Si gnal Lamp . . . . . . . . . . . 8W-80-52
Left Rear Wheel Speed Sensor . . . . . . . . . 8W-80-52
Left Si de Repeater . . . . . . . . . . . . . . . . . . . 8W-80-52
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . 8W-80-53
Left Vi sor/Vani ty Mi rror . . . . . . . . . . . . . . 8W-80-53
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-80-53
Li ftgate Cyl i nder Lock Swi tch . . . . . . . . . . 8W-80-53
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . . 8W-80-53
Li ftgl ass Ajar Swi tch . . . . . . . . . . . . . . . . . 8W-80-54
Li ftgl ass Li mi t Swi tch . . . . . . . . . . . . . . . . 8W-80-54
Li ftgl ass Push Button . . . . . . . . . . . . . . . . 8W-80-54
Li ftgl ass Rel ease Sol enoi d . . . . . . . . . . . . . 8W-80-54
Mani fol d Absol ute Pressure Sensor . . . . . . 8W-80-54
Mass Ai r Fl ow Modul e . . . . . . . . . . . . . . . . 8W-80-55
MSA Control l er (Di esel ) . . . . . . . . . . . . . . 8W-80-55
Memory Seat Modul e - C1 . . . . . . . . . . . . . 8W-80-56
Memory Seat Modul e - C2 . . . . . . . . . . . . . 8W-80-56
Mi ni Overhead Consol e . . . . . . . . . . . . . . . 8W-80-57
Mode Door Actuator . . . . . . . . . . . . . . . . . 8W-80-57
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . . 8W-80-57
Needl e Sensor (Di esel ) . . . . . . . . . . . . . . . . 8W-80-58
Oi l Pressure Sensor . . . . . . . . . . . . . . . . . . 8W-80-58
Output Shaft Speed Sensor . . . . . . . . . . . . 8W-80-58
Overhead Consol e . . . . . . . . . . . . . . . . . . . 8W-80-58
Park/Neutral Posi ti on Swi tch . . . . . . . . . . 8W-80-59
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . . 8W-80-59
Passenger Door Modul e - C1 . . . . . . . . . . . 8W-80-59
Passenger Door Modul e - C2 . . . . . . . . . . . 8W-80-59
Passenger Heated Seat Back . . . . . . . . . . . 8W-80-60
Passenger Heated Seat Cushi on . . . . . . . . 8W-80-60
Passenger Lumbar Motor . . . . . . . . . . . . . 8W-80-60
Passenger Lumbar Swi tch . . . . . . . . . . . . . 8W-80-60
Passenger Power Seat Front Ri ser Motor . 8W-80-61
Passenger Power Seat Hori zontal Motor . . 8W-80-61
Passenger Power Seat Rear Ri ser Motor . . 8W-80-61
Passenger Power Seat Recl i ner Motor . . . . 8W-80-61
Passenger Power Seat Swi tch . . . . . . . . . . 8W-80-61
Passenger Seat Heater Control Modul e . . . 8W-80-62
Pedal Posi ti on sensor (Di esel ) . . . . . . . . . . 8W-80-62
Power Ampl i fi er - C1 . . . . . . . . . . . . . . . . . 8W-80-62
Power Ampl i fi er - C2 . . . . . . . . . . . . . . . . . 8W-80-62
Power Ampl i fi er (LTD+) - C1 . . . . . . . . . . . 8W-80-63
Power Ampl i fi er (LTD+) - C2 . . . . . . . . . . . 8W-80-63
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . 8W-80-64
Powertrai n Control Modul e - C1 . . . . . . . . 8W-80-64
Powertrai n Control Modul e - C2 . . . . . . . . 8W-80-65
Powertrai n Control Modul e - C3 . . . . . . . . 8W-80-66
Powertrai n Control Modul e - C4 (Di esel ) . . 8W-80-67
Component Page
Radi o - C1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-68
Radi o - C2 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-68
Radi o - C3 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-68
Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . 8W-80-68
Rear Washer Pump Motor . . . . . . . . . . . . . 8W-80-69
Rear Wi per Modul e . . . . . . . . . . . . . . . . . . 8W-80-69
Rear Wi per/Washer Swi tch . . . . . . . . . . . . 8W-80-69
Reci rcul ati on Door Actuator (wi th ATC) . . 8W-80-69
Ri ght Ai rbag Sensor . . . . . . . . . . . . . . . . . 8W-80-70
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . 8W-80-70
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8W-80-70
Ri ght Door Courtesy Lamp . . . . . . . . . . . . 8W-80-70
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-70
Ri ght Front Cyl i nder Lock Swi tch . . . . . . . 8W-80-71
Ri ght Front Door Lock Motor . . . . . . . . . . 8W-80-71
Ri ght Front Door Speaker . . . . . . . . . . . . . 8W-80-71
Ri ght Front Park Lamp . . . . . . . . . . . . . . . 8W-80-71
Ri ght Front Power Wi ndow Motor . . . . . . . 8W-80-71
Ri ght Front Si de Marker Lamp . . . . . . . . . 8W-80-72
Ri ght Front Turn Si gnal Lamp . . . . . . . . . 8W-80-72
Ri ght Front Wheel Speed Sensor . . . . . . . . 8W-80-72
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . 8W-80-72
Ri ght Headl amp Level i ng Motor . . . . . . . . 8W-80-72
Ri ght I nstrument Panel Speaker . . . . . . . . 8W-80-72
Ri ght Li cense Lamp . . . . . . . . . . . . . . . . . 8W-80-73
Ri ght Park Lamp . . . . . . . . . . . . . . . . . . . 8W-80-73
Ri ght Park Turn Si gnal Marker . . . . . . . . 8W-80-73
Ri ght Rear Door Lock Motor . . . . . . . . . . . 8W-80-73
Ri ght Rear Door Speaker . . . . . . . . . . . . . 8W-80-73
Ri ght Rear Fog Lamp . . . . . . . . . . . . . . . . 8W-80-73
Ri ght Rear Power Wi ndow Motor . . . . . . . 8W-80-74
Ri ght Rear Power Wi ndow Swi tch . . . . . . . 8W-80-74
Ri ght Rear Si de Marker Lamp . . . . . . . . . 8W-80-74
Ri ght Rear Turn Si gnal Lamp . . . . . . . . . . 8W-80-74
Ri ght Rear Wheel Speed Sensor . . . . . . . . 8W-80-74
Ri ght Si de Repeater . . . . . . . . . . . . . . . . . 8W-80-75
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . 8W-80-75
Ri ght Vi sor/Vani ty Mi rror . . . . . . . . . . . . . 8W-80-75
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . 8W-80-75
Shi ft I nterl ock . . . . . . . . . . . . . . . . . . . . . . 8W-80-75
Sol ar Sensor . . . . . . . . . . . . . . . . . . . . . . . 8W-80-75
Speed Proporti onal Steeri ng Modul e . . . . . 8W-80-76
Speed Proporti onal Steeri ng Sol enoi d . . . . 8W-80-76
Steeri ng Wheel Speed Sensor . . . . . . . . . . 8W-80-77
Steeri ng Wheel Speed Sensor . . . . . . . . . . 8W-80-77
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . 8W-80-77
Swi tch Pod . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-77
Sunroof Control Modul e . . . . . . . . . . . . . . 8W-80-77
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . 8W-80-78
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . 8W-80-78
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . 8W-80-78
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . 8W-80-78
Trai l er Tow Stop Lamp Rel ay . . . . . . . . . . 8W-80-79
ZG 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3
DESCRIPTION AND OPERATION (Continued)
Component Page
Transmi ssi on Sol enoi d Assembl y . . . . . . . . 8W-80-79
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-79
Upstream Heated Oxygen Sensor . . . . . . . 8W-80-79
Vehi cl e I nformati on Center . . . . . . . . . . . . 8W-80-80
Vehi cl e Speed Control Servo . . . . . . . . . . . 8W-80-80
Vehi cl e Speed Control /Horn Swi tch . . . . . . 8W-80-80
Vehi cl e Speed Sensor (Di esel ) . . . . . . . . . . 8W-80-81
Component Page
Vehi cl e Speed Sensor (Gas) . . . . . . . . . . . . 8W-80-80
Water I n-Fuel Sensor (Di esel ) . . . . . . . . . . 8W-80-81
Wi ndshi el d Washer Pump Motor . . . . . . . . 8W-80-81
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . . 8W-80-81
Wi per Fl ui d Level Sensor . . . . . . . . . . . . . 8W-80-81
8W - 80 - 4 8W - 80 CONNECTOR PIN-OUTS ZG
DESCRIPTION AND OPERATION (Continued)
8W - 80 - 5 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08005
C36 20DB/RD
C34 20VT/WT
E2 20OR
F71 20DG/PK
C90 20LG
CIRCUIT
-
-
FUNCTION
-
-
BLEND AIR DOOR POSITION SWITCH SIGNAL
GROUND
PANEL LAMP DRIVER
FUSED IGNITION SWITCH OUTPUT (RUN)
A/C SELECT INPUT
CAV
1
2
3
4
5
6
7
A/C-HEATER
CONTROL - C2
BLACK
6
7
1
3
2
4 5
C
D
B
A
AFTERMARKET TRAILER
TOW CONNECTOR
BLACK
CIRCUIT FUNCTION
STOP LAMP SWITCH OUTPUT
PARK LAMP RELAY OUTPUT
RIGHT TURN SIGNAL
FUSED B(+)
CAV
A
B
C
D
L50 18WT/TN
L90 18DB/RD
L60 18TN
F70 18PK/BK
CIRCUIT FUNCTION
LOW BLOWER MOTOR DRIVER
M1 BLOWER MOTOR DRIVER
HIGH BLOWER MOTOR DRIVER
GROUND
M2 BLOWER MOTOR DRIVER
CAV
1
2
3
4
5
C4 14TN
C5 14LG
C7 12BK/TN
C1 14DG
C6 14LB
A/C HEATER
CONTROL - C1
BLACK
4
2
3
1
5
CIRCUIT FUNCTION
A/C PRESSURE SWITCH SENSE
A/C COMPRESSOR CLUTCH
GROUND
CAV
1
2
2
C21 18DB/OR
C3 18DB/BK
Z1 18BK*
A/C HIGH PRESSURE
SWITCH
BLACK
1 2
CIRCUIT FUNCTION
A/C PRESSURE SWITCH SENSE
A/C COMPRESSOR CLUTCH RELAY CONTROL
A/C PRESSURE SWITCH SENSE
CAV
C3 18DB/BK*
C13 16DB**
C21 18DB/OR
A/C LOW PRESSURE
SWITCH
BLACK
2 1
1
1
2
* GAS
** DIESEL
8W - 80 - 6 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08006
AIRBAG CONTROL MODULE
BLACK
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
-
-
-
-
-
DRIVER AIRBAG LINE 2
DRIVER AIRBAG LINE 1
PASSENGER AIRBAG LINE 1
PASSENGER AIRBAG LINE 2
GROUND
FUSED IGNITION SWITCH OUTPUT (RUN/START)
CCD BUS (-)
CCD BUS (+)
FUSED IGNITION SWITCH OUTPUT (RUN)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
R45 18DG/LB
R43 18BK/LB
R42 18BK/YL
R44 18DG/YL
Z6 16BK/PK
G5 18DB/WT
D2 18WT/BK
D1 18VT/BR
F20 18WT
1
CIRCUIT
-
-
FUNCTION
-
-
FUSED IGNITION FUSED OUTPUT (RUN)
GROUND
BACK-UP LAMP SWITCH OUTPUT
ELECTRIC CHROMATIC MIRROR (+)
ELECTRIC CHROMATIC MIRROR (-)
CAV
1
2
3
4
5
6
7
F83 20BK/VT
Z1 20BK
L10 20BK/RD
P112 20BK/WT
P114 20BK/YL
AUTOMATIC DAY/
NIGHT MIRROR
BLACK
1 7
12
11 22
CIRCUIT FUNCTION
SENSOR RETURN
AMBIENT TEMPERATURE SENSOR SIGNAL
CAV
1
2
D41 20LG/WT
C8 20DG/RD
AMBIENT
TEMPERATURE SENSOR
BLACK
2 1
CIRCUIT FUNCTION
FUSED B(+)
VTSS INDICATOR LAMP DRIVER
ULTRALIGHT LIGHT SENSOR DRIVER
ULTRALIGHT LIGHT SENSOR SIGNAL
CAV
1
2
3
4
F75 18VT
G69 20BK/LG
L109 20WT
L110 20OR/BK
AUTO HEADLAMP
LIGHT SENSOR/VTSS LED
1 4
GRAY
BLACK
CIRCUIT FUNCTION
PANEL LAMP DRIVER
GROUND
CAV
1
2
E2 20OR
Z1 20BK
ASH RECIEVER LAMP
1 2
8W - 80 - 7 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08007
CIRCUIT
-
-
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
-
-
MODE DOOR MOTOR DRIVER
BLEND AIR DOOR MOTOR DRIVER
MODE DOOR MOTOR POSITION SENSE
A/C SELECT INPUT
5 VOLT SUPPLY
BLOWER POWER MODULE OUTPUT
CCD BUS(+)
CCD BUS(-)
FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED B(+)
BLEND AIR DOOR FEEDBACK SIGNAL
MODE DOOR MOTOR DRIVER
HIGH SPEED BLOWER MOTOR RELAY SIGNAL
RECIRCULATION DOOR MOTOR DRIVER
RECIRCULATION DOOR MOTOR DRIVER
HIGH SPEED BLOWER MOTOR RELAY CONTROL
BLEND AIR DOOR MOTOR DRIVER
GROUND
SENSOR RETURN
IN-CAR TEMPERATURE SENSOR SIGNAL
PANEL LAMP DRIVER
SOLAR SENSOR SIGNAL
CAV
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
C37 20YL
C35 20DG/YL
C39 20WT
C90 20LG
C40 20BR/WT
C43 18YL/BR
D1 18VT/BR
D2 18WT/BK
F71 20DG/PK
F60 20WT/RD
C36 20RD/WT
C38 20DB
C42 18PK/DB
C32 20DB/GY
C33 20DB/RD
C41 20GY/DB
C34 20DB/WT
Z4 20PK
D41 20LG/WT
C10 20RD/TN
E2 20OR
C47 20BK/WT
AUTOMATIC TEMPERATURE
CONTROL MODULE
BLUE
C1 C16
D1 D16
CIRCUIT FUNCTION
BATTERY TEMPERATURE SENSE SIGNAL
SENSOR GROUND
CAV
1
2
T222 18RD/YL
K4 18BK/LB
BATTERY
TEMPERATURE SENSOR
BLACK
1 2
CIRCUIT FUNCTION
FUSED IGNITION SWITCH OUTPUT
BACK-UP SWITCH OUTPUT
CAV
1
2
F83 18YL/DG
L10 18BR/LG
BACK-UP LAMP SWITCH
(DIESEL)
1 2
BLACK
8W - 80 - 8 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08008
CIRCUIT
-
FUNCTION
-
5 VOLT SUPPLY
BLEND AIR DOOR FEEDBACK SIGNAL
SENSOR RETURN
BLEND AIR DOOR MOTOR DRIVER
BLEND AIR DOOR MOTOR DRIVER
CAV
1
2
3
4
5
6
C40 20DG/YL
C36 20DB/RD
D41 20LG/WT
C35 20DB/WT
C34 20VT/WT
BLEND DOOR ACTUATOR
(WITH AUTOMATIC
TEMPERATURE CONTROL)
6 5 4 3 2 1
BLACK
CIRCUIT
-
-
FUNCTION
-
-
5 VOLT SUPPLY
FUSED IGNITION SWITCH OUTPUT (RUN)
BLEND AIR DOOR POSITION SWITCH SIGNAL
COMMON DOOR DRIVER
CAV
1
2
3
4
5
6
C40 20WT/YL
F71 20PK/DG
C36 20DB/RD
C34 20VT/WT
BLEND DOOR
ACTUATOR
(WITH MANUAL
A/C-HEATER)
6 5 4 3 2 1
BLACK
CIRCUIT FUNCTION
BLOWER MOTOR DRIVER
GROUND
CAV
1
2
A19 12RD
C7 12BK
BLOWER MOTOR
(WITH MANUAL
A/C-HEATER)
NATURAL
2 1
CIRCUIT FUNCTION
HIGH SPEED BLOWER MOTOR RELAY SIGNAL
GROUND
CAV
1
2
C42 12RD
Z4 12BK
CIRCUIT FUNCTION
LOW BLOWER MOTOR DRIVER
M2 BLOWER MOTOR DRIVER
HIGH BLOWER MOTOR DRIVER
M1 BLOWER MOTOR DRIVER
CAV
1
2
3
4
C4 14TN
C6 14LB
C7 12BK
C5 14LG
BLOWER MOTOR
(WITH AUTOMATIC
TEMPERATURE CONTROL)
NATURAL
2 1
BLOWER MOTOR
RESISTOR BLOCK
(WITH MANUAL A/C-HEATER)
BLACK
2
3
1
4
8W - 80 - 9 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08009
CIRCUIT
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
WINDSHIELD WIPER SWITCH SIGNAL
SENSOR RETURN
AMBIENT TEMPERATURE SENSOR SIGNAL
SWITCHED COURTESY LAMP FEED
AUTO HEADLAMP SWITCH SENSE
REAR WINDOW DEFOGGER SWITCH SENSE
DIMMER SWITCH LOW BEAM OUTPUT
HOOD AJAR SWITCH SENSE
KEY-IN IGNITION SWITCH SENSE
FOG LAMP SWITCH OUTPUT
GROUND
PARK LAMP RELAY OUTPUT
FUSED IGNITION SWITCH OUTPUT (START/RUN)
CCD BUS (+)
CCD BUS (-)
VTSS INDICATOR LAMP DRIVER
DIMMER SWITCH HIGH BEAM OUTPUT
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
V51 18WT
D41 20LG/WT
C8 20DG/RD
M11 20PK/LB
L24 20LB/RD
C80 20DB/YL
L4 16VT/OR
G70 20BR/TN
G26 20LB
L35 20BR/WT
Z2 20BK/OR
L90 20DB/RD
F99 20OR
D1 18VT/BR
D2 18WT/BK
G69 20BK/LG
L3 16RD/OR
BODY CONTROL
MODULE - C1
BLACK
24
16
8
17
9
1
CIRCUIT
-
-
FUNCTION
-
-
BLOWER MOTOR DRIVER
FUSED B(+)
BLOWER POWER MODULE OUTPUT
GROUND
CAV
1
2
3
4
5
6
C42 12BR/RD
A19 10RD
C43 18BR/YL
Z4 18BK
BLOWER POWER MODULE
BLACK
1 3
4 6
ZG-RHD 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08010
CIRCUIT
-
-
-
-
-
FUNCTION
-
-
-
-
-
ULTRALIGHT SENSOR DRIVER
RADIO CONTROL MUX
WIPER PARK SWITCH SENSE
COURTESY LAMP RELAY CONTROL
A/C SELECT INPUT
FUSED B(+)
ULTRALIGHT SENSOR SIGNAL
AUTO HEADLAMP RELAY CONTROL
HORN RELAY CONTROL
REAR WINDOW DEFOGGER RELAY CONTROL
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
PANEL LAMP DRIVER
WASHER SWITCH OUTPUT
WIPER SWITCH MODE SENSE
PANEL LAMP DIMMER SWITCH SIGNAL
PARK LAMP RELAY CONTROL
FOG LAMP RELAY CONTROL
INTERMITTENT WIPER RELAY CONTROL
GROUND
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
L109 20WT
709 20RD/BK
V66 16VT/WT
M112 20BR/LG
C90 20LG
F75 18VT
L110 20OR/BK
714 20BK/OR
X4 20GY/OR
C14 20WT/RD
V23 20BR/PK
E2 20OR
V11 18TN/BK
V50 18LG/WT
707 20BK/WT
L79 20TN
L95 20DG/YL
V18 20YL/LG
Z1 16BK
BODY CONTROL
MODULE - C2
WHITE
24
16
8
17
9
1
8W - 80 - 11 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08011
CIRCUIT FUNCTION
RED BRAKE WARNING LAMP DRIVER
RED BRAKE WARNING LAMP DRIVER
CAV
1
2
G9 16GY/BK
G9 16GY/BK
BRAKE WARNING
SWITCH
BLACK
2 1
C102
CIRCUIT CAV
1
2
3
1 2 3
BLACK
CIRCUIT CAV
1
2
3
L65 18LG/DB
L90 18DB/RD
Z1 18BK
L65 18LG/DB
L90 18DB/RD
Z1 18BK
3 2 1
BLACK
C102
CIRCUIT
-
-
-
-
FUNCTION
-
-
-
-
LEFTGATE AJAR SWITCH SENSE
PARK BRAKE SENSE
RIGHT REAR DOOR AJAR SWITCH SENSE
LEFT FRONT DOOR AJAR SWITCH SENSE
LIFTGATE COURTESY LAMP DISABLE
GROUND
RIGHT FRONT DOOR AJAR SWITCH SENSE
VTSS DISARM SENSE
LEFT REAR DOOR AJAR SWITCH SENSE
SEAT BELT SWITCH SENSE
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
G78 20TN/BK
G9 20GY/BK
G76 18TN/YL
G75 18TN
M4 20WT/LG
Z2 18BK/OR
G74 18TN/RD
G71 20VT/YL
G77 18TN/OR
G10 20LG/RD
BLACK
5
9
14
1
6
10
BODY CONTROL
MODULE - C3
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
G40 18LB/BK
F99 20OR
G18 20PK/BK
K4 18BK/LB
L10 18BR/LG
G118 20PK/DB
A64 14OR/DB
Z1 12BK
F6 18WT/RD
A142 16DG/OR
F83 18YL/DG
C3 18DB/BK
C131
(DIESEL)
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
G40 18LB/BK
F99 20OR
G18 20PK/BK
K4 20BK/LB
L10 18BR/LG
G118 20PK/DB
A64 14DG/WT
Z1 12BK
F6 18WT/RD
A142 16DG/OR
F83 18YL/DG
C3 18DB/BK
14
1 8
7
14
1 8
7
C131
(DIESEL)
BLACK
BLACK
8W - 80 - 12 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08012
CIRCUIT
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
L53 20BR
Z1 18BK
Z2 18BK/OR
D2 18WT/BK
D1 18VT/BR
T106 20GY/OR
T107 20BK/RD
V32 20YL/RD
L50 18WT/TN
C13 16DB/RD
G28 20LG/OR
K167 20BR/YL
K900 20PK/BK
C132
(DIESEL)
C132
(DIESEL)
CIRCUIT
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
L53 20BR
Z1 18BK
Z2 18BK/OR
D2 18WT/BK
D1 18BT/BR
T106 20GY/OR
T107 20BK/RD
V32 20YL/RD
L50 18WT/TN
C13 16DB/RD
G28 20LG/OR
K167 20BR/YL
K900 20PK/BK
14
1 8
7
14
1 8
7
CIRCUIT
-
-
-
CAV
1
2
3
4
5
6
7
8
9
10
10
T20 18LB
F99 20OR
A142 18DG/OR
F5 14RD/YL
L10 18BR/LG
C2 18DB/YL
G28 20LG/OR
K4 20BK/LB
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
9
10
10
T20 18LB
F99 18OR
A142 18DG/OR
F5 14RD/YL
L10 18BR/LG
C2 18DB/YL
G28 20LG/OR
K4 18BK/LB*
K4 20BK/LB**
CIRCUIT
-
CAV
1
2
3
4
5
6
7
8
9
10
Z1 18BK
Z2 18BK/OR
T41 20BK/WT
G7 18WT/OR
K20 18DG
T66 20BR/OR
F83 18YL/DG
T106 20GY/OR
T107 20BK/RD
CIRCUIT
-
CAV
1
2
3
4
5
6
7
8
9
10
Z1 18BK
Z2 18BK/OR
T41 20BK/WT
G7 18WT/OR
K20 18DG
T66 20BR/OR
F83 18YL/DG
T106 20GY/OR
T107 20BK/RD
* 5.2L
** 4.0L
4WD
BLACK
5
10
1
6
BLACK
5
10
1
6
BLACK
5
10
1
6
BLACK
5
10
1
6
C131
(GAS)
C131
(GAS)
BLACK
BLACK
C132
(GAS)
ZG-RHD 8W - 80 - 13 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08013
CIRCUIT
-
CAV
1
2
3
4
5
6
7
8
9
10
C2 18DB/YL
D83 20BK/PK
K95 20PK
C21 18DB/OR
T40 12LB/BK
K95 20PK
V32 20YL/RD
C21 18DB/OR
T40 12LG/BK
CIRCUIT
-
-
-
-
CAV
1
2
3
4
5
6
7
8
9
10
C2 18DB/YL
D83 20BK/WT
D84 20BK/WT
K95 20PK
C21 18DB/OR
T40 12LB/BK
C141
(DIESEL)
BLACK
C141
(DIESEL)
CIRCUIT CAV
1
2
3
L64 18LG/DB
L90 18DB/RD
Z1 18BK
CIRCUIT CAV
1
2
3
L64 18LG/DB
L90 18DB/RD
Z1 18BK
C150
C150
CIRCUIT
-
CAV
1
2
2
M1 18PK
Z1 18BK
CIRCUIT CAV
1
2
2
M1 18PK
Z1 18PK
Z4 18BK**
C159
CIRCUIT CAV
1
2
A19 12RD/VT
Z4 12BK
CIRCUIT CAV
1
1
2
A1910RD*
A19 12RD**
Z4 12BK
C160 C160
* GAS
** DIESEL
1 2
3 1
BLACK
3 1
BLACK
2
1 2
BLACK
1 2
BLACK
C159
BLACK
1 2
5
1
6
10
5
1
6
10
CIRCUIT CAV
1
2
3
4
K255 20WT/DG
K151 20WT
K6 20VT/WT
K22 20OR/DB
CIRCUIT CAV
1
2
3
4
K255 20WT/DG
K151 20WT
K6 20VT/WT
K22 20OR/DB
C182
(DIESEL)
C182
(DIESEL)
1 4
3 6
1 4
3 6
8W - 80 - 14 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08014
CIRCUIT
-
-
-
-
-
-
-
-
CAV
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
C7 12BK/TN
C6 14LB
C5 14LG
C4 14TN
C36 20DB/RD
F71 20PK/DG
C34 20VT/WT
C1 14DG C206
(WITH MANUAL
A/C HEATER)
C206
(WITH MANUAL
A/C HEATER)
CIRCUIT
-
-
-
-
-
-
-
-
CAV
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
C7 12BK/TN
C6 14LB
C5 14LG
C4 14TN
C36 20DB/RD
F71 20PK/DG
C34 20VT/WT
Z4 12BK
CIRCUIT
-
CAV
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
C39 20WT
C37 20YL
C35 20DG/YL
C36 20RD/WT
C34 20DB/WT
F71 20PK/DG
C33 20DB/RD
C32 20DB/GY
C38 20DB
C40 20BR/WT
C41 20GY/DB
C42 18PK/DB
C43 18YL/BR
Z4 20PK
D41 20LG/WT
C206
(WITH AUTOMATIC
TEMPERATURE CONTROL)
CIRCUIT
-
CAV
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
C39 20YL
C37 20TN/BK
C35 20DB/WT
C36 20DB/RD
C34 20VT/WT
F71 20PK/DG
C33 20VT/OR
C32 20LB/DG
C38 20DG
C40 20DG/YL
C41 20BR
C42 12BR/RD
C43 18BR/YL
Z4 20BK
D41 20LG/WT
C206
(WITH AUTOMATIC
TEMPERATURE CONTROL)
BLACK
BLACK
BLACK
BLACK
ZG-RHD 8W - 80 - 15 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08015
* GAS
** DIESEL
CIRCUIT CAV
A
B
G28 20LG/OR
107 20BK/RD
CIRCUIT CAV
A
B
G42 20LG/RD
T10 20YL/BK
C212
C212
CIRCUIT CAV
1
2
A41 14YL
T141 14YL/RD
CIRCUIT CAV
1
2
T141 14YL/RD
T141 14YL/RD
C229
C229
(MANUAL TRANS ONLY)
CIRCUIT
-
CAV
1
2
3
4
5
6
D1 18VT/BR
D2 18WT/BK
P112 20YL/WT
P114 20YL/BK
F86 16LG/BK
C231
C231
CIRCUIT
-
CAV
1
2
3
4
5
6
D1 18VT/BR
D2 18WT/BK
P112 20YL/WT
P114 20YL/BK
F86 16LG/BK
CIRCUIT
-
CAV
E1
E2
E4
E4
A1 12RD/WT
F61 16WT/OR
T141 14YL/RD
CIRCUIT CAV
E1
E2
E4
E4
A1 12RD/WT
F61 16WT/OR
A41 14YL*
T141 14YL/RD**
C233
C233
2 1
BLACK
1 2
BLACK
RED
A B
A B
RED
2 1
6 3
1
3
2
6
BLACK
1
2
3
4
BLACK
ZG-RHD 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08016
CIRCUIT CAV
F1
F2
F3
F4
F5
F5
F6
F6
F7
F8
F8
F9
F9
F10
F11
F12
F12
F12
F13
F13
F14
F15
F15
F17
F18
F19
F19
F20
V11 18TN/BK
L3 16RD/OR
L4 16VT/OR
V4 18RD/YL
G9 16GY/BK*
G9 18GY/BK**
G18 16PK/BK*
G118 16PK/DB**
G29 16BK/TN
K4 20BK/LB*
K4 18BK/LB**
V32 18YL/RD*
V32 20YL/RD**
L65 18LG/DB
C8 20DG/RD
G34 20RD/GY
L3 16RD/OR
L3 16RD/OR**
L53 18BR*
L53 20BR**
D83 20BK/PK
D84 18BK/WT*
D84 20BK/WT**
V20 18WT/BK
V6 16DB
K95 18PK*
K95 20PK**
T9 20OR*
C234
CIRCUIT
-
CAV
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
V11 18TN/BK
L3 16RD/OR
L4 16VT/OR
V4 18RD/YL
G9 16GY/BK
G18 16PK/BK*
G29 20BK/TN
K4 18BK/LB
V32 20YL/RD
L65 18LG/DB
C8 20DG/RD
L3 16RD/OR
L53 20BR
D83 20BK/PK
D84 20BK/WT
V20 18WT/BK
V6 16DB
K95 20PK
T9 20OR
* GAS
** DIESEL
CIRCUIT
-
-
-
CAV
G1
G2
G3
G4
G5
G6
G7
G8
G9
G10
G11
G12
G13
G14
G15
G16
G17
G18
G19
G20
G68 18BR/YL*
V30 20DB/LG
T106 20GY/OR
205 20WT/VT
D98 20WT*
G68 18BR/YL
V18 20YL/LG
D41 20LG/WT
S1 20BK/YL*
S2 20BK/LG*
S3 20PK/WT*
S4 20VT*
V3 18BR/WT
V66 18VT/WT
F83 18YL/DG
D1 18VT/BR
D2 18WT/BK
CIRCUIT
-
-
-
CAV
G1
G2
G3
G4
G5
G6
G7
G8
G9
G10
G11
G12
G13
G14
G15
G16
G17
G18
G19
G20
D98 20WT
205 20WT/VT
G70 20BR/TN
T106 20GY/OR
V30 20DB/LG
G68 20BR/YL
D2 18WT/BK
D1 18VT/BR
F83 18YL/DG
V66 16VT/WT
V3 18BR/WT
S4 20VT*
S3 20PK/WT*
S2 20BK/LG*
S1 20BK/YL*
D41 20LG/WT***
V18 20YL/LG
= UNITED STATES
= DAYTIME RUNNING LAMPS
C234
C235
C235
WHITE
9 1
20 10
1
10
9
20
BLACK
1
BLACK
10
9
20
1 10
9 20
ZG-RHD 8W - 80 - 17 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08017
CIRCUIT
-
-
-
-
-
-
-
-
CAV
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
H16
H17
H18
L101 20RD
L102 20WT
L103 20LB
L104 20LG
L105 20PK
L106 20YL
F99 20OR**
Z1 18BK
Z2 18BK/OR
K4 20BK/LB**
C236
CIRCUIT
-
-
-
-
-
-
-
-
-
CAV
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
H16
H17
H18
L101 20RD
L102 20WT
L103 20LB
L104 20LG
L105 20PK
L106 20YL
F99 20OR
Z1 18BK
Z2 18BK/OR C236
CIRCUIT CAV
A
B
R44 18DG/YL
R42 18BK/YL
C300
CIRCUIT CAV
A
B
R44 18DB
R42 18VT
C300
CIRCUIT CAV
1
2
3
4
C15 12BK/WT
Z1 14BK
P7 18LB/BK
P8 18LB/WT
C301
CIRCUIT CAV
1
2
3
4
C15 12BK/WT
Z1 14BK
P7 20LB
P8 20LB/WT
C301
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
D1 18VT/BR
D2 18WT/BK
F71 18PK/DG
E2 18OR
P112 18YL/WT
P114 18YL/BK
C302
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
D1 18VT/BR
D2 18WT/BK
F71 20PK/DG
E2 20OR
P112 20YL/WT
P114 20YL/BK
C302
** DIESEL
3
WHITE
8
1
4
WHITE
1
4
3
8
WHITE
1
4
1
4
WHITE
A B
YELLOW
A B
YELLOW
WHITE
9 18
1 10
WHITE
9
18
1 10
ZG-RHD 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08018
CIRCUIT
-
-
-
-
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
G9 20GY/BK
B1 20YL/DB
B2 20YL
B41 20YL/VT
B42 20TN/WT
B43 20PK/OR
G40 18LB/BK
B3 20LG/DB
B4 20LG
K167 20BR/YL
L50 18WT/TN
A64 16DG/WT
C304
CIRCUIT
-
-
-
-
CAV
2
2
2
3
4
5
6
7
8
9
10
11
12
13
15
15
16
17
18
G9 20GY/BK*
G9 20GY/BK*
G9 18GY/BK**
B1 20YL/DB
B2 20YL
B41 20YL/VT
B42 20TN/WT
B43 20PK/OR
G40 18LB/BK
B3 20LG/DB
B4 20LG
K4 20BK/LB*
K167 20BR/YL**
L50 18WT/TN
A64 14DG/WT**
A64 16DG/WT*
C304
CIRCUIT
-
-
-
-
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
V24 18BR/OR
V20 18BK/WT
X55 16BR/RD
X55 16BR/RD
X53 16DG
X53 16DG
X54 16VT
X54 16VT
X56 16DB
X56 16DB
Z5 14BK/LB
Z5 14BK/LB
X51 16BR/YL
X51 16BR/YL
X57 16BR/LB
X57 16BR/LB
L50 18WT/TN
X52 16DB/WT
X52 16DB/WT
X58 16DB/OR
X58 16DB/OR
CIRCUIT
-
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
X53 20DG
X55 20BR/RD
V20 18WT/BK
V24 18BR/OR
X58 20DB/OR
X52 20DB/WT
L50 18WT/TN
X57 20BR/LB
X51 20BR/YL
Z5 16BK
X56 20DB
X54 20VT/YL
C305
(GAS)
C305
(GAS)
BLACK
9
18
1
10
BLACK
9
18
1
10
1
BLACK
7
6
14
1 7
6 14
18
* GAS
** DIESEL
8W - 80 - 19 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08019
CIRCUIT
-
-
-
-
-
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
V24 18BR/OR
V20 18BK/WT
X55 16BR/RD
X55 16BR/RD
X53 16DG
X53 16DG
X54 16VT
X54 16VT
X56 16DB
X56 16DB
Z5 14BK/LB
Z5 14BK/LB
X51 16BR/YL
X51 16BR/YL
X57 16BR/LB
X57 16BR/LB
L50 18WT/TN
X52 16DB/WT
X52 16DB/WT
X58 16DB/OR
X58 16DB/OR
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
V24 18BR/OR
V20 18WT/BK
X55 20BR/RD
X53 20DG
X54 20VT/YL
X56 20DB
Z5 16BK
X51 20BR/YL
X57 20BR/LB
L50 18WT/TN
X52 20DB/WT
X58 20DB/OR
C305
(DIESEL)
6
14
1 7
C305
(DIESEL)
1
BLACK
7
6
14
CIRCUIT CAV
1
2
3
3
4
4
4
5
6
7
8
9
10
11
12
13
14
X82 16LB/RD
X80 16LB/DG
A 61 18LG
L61 18LG
L60 18TN
L60 18TN
L60 18TN
G46 20LB/BK
V13 18BR/LG
L36 18LG/OR
Z2 18BK/OR
K255 20WT/DG**
K151 20WT**
K6 20VT/WT**
K22 20OR/DB**
X85 16LG/BK
X87 16LG/RD
C307
CIRCUIT CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
X82 20LB/BK
X80 20LB/RD
L61 18DG
L60 18TN
G46 20BK/LB
V13 18BR/LG
L36 18LG
Z2 18BK/OR
K255 20WT/DG**
K151 20WT**
K6 20VT/WT**
K22 20OR/DB**
X85 20LG/BK
X87 20LG/RD
C307
WHITE
7
14
1
8
WHITE
7
8
1
14
** DIESEL
ZG-RHD 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08020
CIRCUIT CAV
1
2
3
4
5
5
6
L74 18PK/BK
L22 18LB
L10 18BR/LG
Z1 18BK
L60 18TN
L60 18TN
L36 18LG/OR
C320
CIRCUIT CAV
1
2
3
4
5
6
L74 18PK/BK
L21 18LB/WT
L10 18BR/LG
Z1 18BK
L61 18LG
L36 18LG/BK
C320
CIRCUIT
-
-
-
CAV
1
2
3
4
5
6
G71 20VT/YL
L90 18DB/RD
G78 20TN/BK
CIRCUIT
-
-
-
CAV
4
5
6
9
10
11
G71 20VT/YL
L78 20DB/RD
G90 20DB/RD
C321
C321
* OPTIONAL
** DIESEL
BLACK
1
6
3
4
GRAY
GRAY
1
3
4
6
BLACK
4
6 5
11
10
9
CONNECTOR
RETAINER
CIRCUIT CAV
1
2
3
4
5
6
7
8
9
10
L36 18LG/OR
L50 18WT/TN
L90 18DB/RD
L90 18DB/RD
L90 18DB/RD
L90 18DB/RD
L90 18DB/RD
L50 18WT/TN
L50 18WT/TN
L50 18WT/TN
G46 20LB/BK
F87 18WT/PK
C316
1
10
5
6
5
6
1
10
BLACK
BLACK
CIRCUIT
-
CAV
1
2
3
4
5
6
7
8
9
10
L36 18LG/OR
L36 18LG/OR
L50 18WT/TN
L90 18DB/RD*
L90 20DB/RD
L22 18LB
L21 18LB/WT
L74 18PK/BK
L73 18PK/WT
L87 18DG/WT
Z1 18BK
C316
J978W-3 ZGR08021
CIRCUIT
-
CAV
1
2 C15 12BK/WT
CIRCUIT
-
CAV
2
3 C15 12BK/LB
C322
CONNECTOR
RETAINER
BLACK
BLACK
1 2
2 3
C322
CIRCUIT
-
CAV
1
2
3
F70 14PK/BK
P2 14BKWT
CIRCUIT
-
CAV
1
7
8
P2 16BK/WT
F70 16PK/BK
C323
GRAY
1 2
3
GRAY
CONNECTOR
RETAINER
1
8 7
C323
CIRCUIT
-
-
-
CAV
1
2
3
4
5
6
V13 18BR/LG
V20 18BK/WT
V24 18BR/OR
CIRCUIT
-
-
-
CAV
4
5
6
9
10
11
V13 18BR/LG
V24 18BR/OR
V20 18BK/WT
C324
BLACK
1
6
3
4
CONNECTOR
RETAINER
BLACK
6 5 4
11
10
9
CIRCUIT
-
CAV
1
2 Z1 12BK
CIRCUIT
-
CAV
2
3 Z1 12BK
C325
CIRCUIT CAV
1
2
3
L87 18DG/WT
Z1 18BK
P34 14PK/BK
CIRCUIT CAV
1
7
8
P34 16PK/BK
Z1 18BK
L87 18DG/WT
C326
CONNECTOR
RETAINER
BLACK
GRAY
BLACK
1 2
1 2
3
2 3
GRAY
CONNECTOR
RETAINER
1
8 7
C324
C325
C326
8W - 80 - 21 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
8W - 80 - 23 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08023
CIRCUIT
-
-
CAV
1
2
3
4
5
6
6
7
8
8
9
10
11
12
13
14
Z1 12BK
F81 10TN
E21 18OR/RD
Q17 14DB/WT
X53 16DG**
X87 16LG/RD*
Q27 14RD/BK
X55 16BR/RD**
X85 16LG/BK*
P114 18YL/BK
P112 18YL/WT
D2 18WT/BK
D1 18VT/BR
G71 20VT/YL
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Z1 12BK
F81 12TN
E21 18OR
Q17 16DB/WT
X53 20DG
Q27 16RD/BK
X55 20BR/RD
P114 20YL/BK
P112 20YL/WT
D2 18WT/BK
D1 18VT/BR
G71 20VT/YL
C334
C335
CIRCUIT CAV
1
2
3
4
F35 16RD
Z1 16BK
P8 18LB/WT
F71 18PK/DG
CIRCUIT CAV
1
2
3
4
F35 14RD
Z1 14BK
P8 18LB/WT
F87 18WT/BK
BLACK
1
8
4 1
BLACK
BLACK
4 1
BLACK
7
14
1
8
7
14
C334
C335
C343
CIRCUIT CAV
A
A
B
B
C
D
E
X93 16WT/RD*
X51 16BR/YL**
X91 16WT/BK*
X57 16BR/LB**
P2 16BK/WT
Z1 16BK
E21 18OR/RD
CIRCUIT CAV
A
B
C
D
E
X52 20DB/WT
X58 20DB/OR
P2 18BK/WT
Z1 16BK
E20 20OR/DG
A
H
D
E
BLACK
A
H
D
E
BLACK
WITH PREMIUM RADIO
WITH STANDARD RADIO
*
**
C343
ZG-RHD 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08024
CIRCUIT
-
-
-
CAV
A
A
B
B
C
D
E
F
G
H
X94 16TN/RD*
X52 16DB/WT**
X92 16TN/BK*
X58 16DB/OR**
P2 16BK/WT
Z1 16BK
E20 18OR/DB
CIRCUIT
-
-
-
CAV
A
B
C
D
E
F
G
H
X52 20DB/WT
X58 20DB/OR
P2 18BK/WT
Z1 16BK
E20 20OR/DG
C345
BLACK
A
H
D
E
BLACK
A
H
D
E
GRAY
1
8
GRAY
7
14
1
8
7
14
CIRCUIT
-
-
CAV
1
2
3
4
5
6
6
7
8
8
9
10
11
12
13
14
Z1 12BK
F81 12TN
E20 18OR/DB
Q18 14GY/BK
X54 16VT**
X82 16LB/RD*
Q28 14DG/WT
X56 16DB**
X80 16LB/DG*
P2 14BK/WT
P34 14PK/BK
D2 18WT/BK
D1 18VT/BR
G71 20VT/YL
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Z1 12BK
F81 12TN
E20 18OR/DB
Q18 16GY/BK
Q28 16DG/WT
P2 14BK/WT
P34 14PK/BK
D2 18WT/BK
D1 18VT/BR
G71 20VT/YL
C351
* WITH PREMIUM RADIO
** WITH STANDARD RADIO
C351
C345
CIRCUIT CAV
A
B
P114 20YL/BK
P112 20YL/WT
CIRCUIT CAV
A
B
P114 20YL/BK
P112 20YL/WT
C353
A
BLACK BLACK
B
B A
C353
X54 20VT
X82 18LB/RD
X56 20DB/RD
X80 16LB/DG
ZG-RHD 8W - 80 - 25 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08025
BLACK
BLACK
A B
A B
CIRCUIT CAV
A
B
L87 18DG/WT
Z1 18BK
CIRCUIT CAV
A
B
L87 20DG/WT
Z1 20BK
C359
CIRCUIT CAV
A
B
Z1 20BK
L90 20DB/RD
CIRCUIT CAV
A
B
Z1 20BK
L90 20DB/RD
C364
BLACK
B A
BLACK
A B
C359
C364
BLACK
1 4
BLACK
1 4
CIRCUIT CAV
1
2
3
4
Z1 16BK
Q41 16WT
Q42 16LB
F86 16LG/BK
C371
CIRCUIT CAV
1
2
3
4
Z1 16BK
Q41 16LB
Q42 16WT
F86 16RD/YL
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
9
10
L50 18WT/TN
L90 18DB/RD
L10 18BR/LG
L61 18LG
L60 18TN
F70 16PK/BK
B40 12LB
Z1 12BK
C372
(WITH FACTORY
TRAILER TOW)
CIRCUIT
-
-
CAV
1
2
3
4
5
6
7
8
9
10
L50 18WT/TN
L90 18DB/RD
L10 18BR/LG
L61 18LG
L61 18LG*
L60 18TN
L60 18TN*
F70 16PK/BK
B40 12LB
Z1 12BK
BLACK
10
BLACK
6
1
10
5
5
6
1
C371
C372
(WITH FACTORY
TRAILER TOW)
WITH FACTORY TRAILER
TOW ONLY
*
8W - 80 - 26 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08026
CIRCUIT FUNCTION
5 VOLT SUPPLY
SENSOR GROUND
CAMSHAFT POSITION SENSOR SIGNAL
CAV
1
2
3
K25 20WT/BK
K4 20BK/LB
K24 18GY/BK
BLACK
CAMSHAFT
POSITION SENSOR
4.0L, 5.2L
(GAS)
1 3
CIRCUIT FUNCTION
COURTESY LAMP RELAY OUTPUT
FUSED B(+)
LIFTGATE COURTESY LAMP DISABLE
CAV
A
B
C
M2 20YL
M1 20PK
M4 20WT/LG
BLACK
C A
CARGO LAMP
CIRCUIT FUNCTION
STOP LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT
GROUND
GROUND
CAV
1
2
L87 20DG/WT
L87 20DG/WT
Z1 20BK
Z1 20BK
BLACK
CENTER HIGH MOUNTED STOP LAMP
NO. 1
1 2
CIRCUIT FUNCTION
STOP LAMP SWITCH OUTPUT
GROUND
CAV
1
2
L87 20DG/WT
Z1 20BK
BLACK
CENTER HIGH MOUNTED STOP LAMP
NO. 2
1 2
CIRCUIT CAV
1
2
3
T40 14LG/BK
G60 20GY/YL
K167 20BR/YL
CIRCUIT CAV
1
2
3
T40 12LG/BK
G60 20GY/YL
K167 20BR/YL
C917
(DIESEL)
C917
(DIESEL)
1 4
3 6
1 4
3 6
ZG-RHD 8W - 80 - 27 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08027
CIRCUIT FUNCTION
IGNITION SWITCH OUTPUT START
CLUTCH INTERLOCK SWITCH SENSE
CAV
1
2
A41 14YL
T141 14YL
CLUTCH INTERLOCK
SWITCH (DIESEL)
(MANUAL TRANS)
1 2
BLACK
CIRCUIT FUNCTION
STOP LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT
GROUND
GROUND
CAV
1
2
L87 20DG/WT
L87 20DG/WT
Z1 20BK
Z1 20BK
BLACK
CENTER HIGH MOUNTED STOP LAMP
NO. 3
1 2
CIRCUIT FUNCTION
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
GROUND
CAV
1
2
F30 18RD/DB
Z1 18BK
CIGAR LIGHTER
BLACK
1
2
CIRCUIT
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
RIGHT REAR WHEEL SPEED SENSOR (-)
LEFT REAR WHEEL SPEED SENSOR (-)
RIGHT FRONT WHEEL SPEED SENSOR (+)
LEFTT FRONT WHEEL SPEED SENSOR (+)
G SWITCH NO. 1 SENSE
G SWITCH NO. 2 SENSE
GROUND
SYSTEM RELAY
LEFT REAR WHEEL SPEED SENSOR (+)
LEFT FRONT WHEEL SPEED SENSOR (+)
STOP LAMP SWITCH OUTPUT
G SWITCH SENSOR GROUND
ABS WARNING LAMP DRIVER
RIGHT REAR WHEEL SPEED SENSOR (+)
RIGHT FRONT WHEEL SPEED SENSOR (-)
SCI RECEIVE
FUSED IGNITION SWITCH OUTPUT (RUN)
GROUND
FUSE LINK TO ABS MOTOR RELAY
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
B1 20YL/DB
B3 20LG/DB
B7 20WT
B9 20RD
B41 20YL/VT
B42 20TN/WT
Z2 12BK
A20 14RD/LG
B4 20LG
B8 20RD/DB
L50 18WT/TN
B43 20PK/OR
205 20WT/VT
B2 20YL
B6 20WT/DB
D83 20BK/PK
F12 20DB/WT
Z2 12BK
A10 10RD/DB
CONTROLLER
ANTI-LOCK
BRAKE
10
16
1 17
9 25
BLACK
ZG-RHD 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08028
CIRCUIT
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
CCD BUS(+)
GROUND
GROUND
SCI TRANSMIT
SCI RECIEVE
CCD BUS (-)
SCI TRANSMIT
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
D1 18VT/BR
Z1 18BK
Z2 18BK/OR
D84 20BK/WT
D83 20BK/PK
D2 18WT/BK
D98 20WT
F75 18VT
DATA LINK CONNECTOR
16 9
8 1
BLACK
** DIESEL
CIRCUIT
-
FUNCTION
-
SENSOR GROUND
CRANKSHAFT POSITION SENSOR SIGNAL
CAV
1
2
3
K4 20BK/LB
K24 20GY/BK
CIRCUIT FUNCTION
-
5 VOLT SUPPLY
SENSOR GROUND
CRANKSHAFT POSITION SENSOR SIGNAL
CAV
1
2
3
K25 20WT/BK
K4 20BK/LB
K27 18RD/LG
CRANKSHAFT POSITION SENSOR
(DIESEL)
CRANKSHAFT POSITION SENSOR
(GAS)
CIRCUIT FUNCTION
ENGINE COOLANT LEVEL SENSE
GROUND
CAV
1
2
G18 16PK/BK
Z1 16BK
COOLANT LEVEL SENSOR
1
BLACK
2
1
BLACK
2 3
1
BLACK
2
3
ZG-RHD 8W - 80 - 29 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08029
CIRCUIT FUNCTION
GROUND
COURTESY LAMP RELAY OUTPUT
FUSED B(+)
CAV
A
B
C
Z1 20BK
M2 2OYL
M1 20PK
DOME/READING
LAMP
NATURAL
A C
CIRCUIT FUNCTION
LEFT FRONT WINDOW DRIVER (UP)
LEFT FRONT WINDOW DRIVER (DOWN)
LEFT REAR WINDOW DRIVER (UP)
LEFT REAR WINDOW DRIVER (DOWN)
LEFT FRONT DOOR UNLOCK DRIVER
LEFT FRONT DOOR LOCK DRIVER
GROUND
CCD BUS (+)
CCD BUS (-)
LEFT REAR DOOR SWITCH ILLUMINATION
MUX COURTESY LAMP DRIVER
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
Q11 16LB
Q21 16WT
Q17 16DB/WT
Q27 16RD/BK
P34 18PK/BK
P35 18OR/VT
Z1 12BK
D1 18VT/BR
D2 18WT/BK
E21 18OR
M1 20PK
F81 12TN
1 6
12 10 9 7
DRIVER
DOOR
MODULE - C1
WHITE
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
GROUND
SENSOR GROUND
DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL
CAV
1
2
3
4
A142 18DG/OR
Z12 18BK/TN
K4 18BK/LB
K141 18BK/PK
BLACK
DOWNSTREAM
HEATED OXYGEN
SENSOR
2
4
1
3
CIRCUIT FUNCTION
HORIZONTAL DRIVER
HEATER SWITCHED GROUND
VERTICAL POSITION SENSOR SIGNAL
SENSOR GROUND
HORIZONTAL POSITION SENSOR SIGNAL
HEATER 12 VOLT SUPPLY
COMMON DRIVER
VERTICAL DRIVER
CAV
A
B
C
D
E
F
G
H
F75 20YL
Z1 20BK
F84 20VT
F86 20GY
F85 20GN
C16 20BK
F73 20DB
F71 20WT
BLACK
A
H
D
E
DRIVER
DOOR
MODULE - C2
ZG-RHD 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08030
D A
CIRCUIT FUNCTION
GROUND
5 VOLT SUPPLY
SET LED DRIVER
SWITCHED MUX LED SUPPLY
CAV
A
B
C
D
Z1 20BK
P22 20BR
G49 20OR
M1 20GY
BLACK
DRIVER
DOOR
MODULE - C3
CIRCUIT FUNCTION
GROUND
HEATED SEAT DRIVER
CAV
A
B
Z1 16BK
P88 16BR/BK
BLACK
DRIVER HEATED
SEAT BACK
A B
CIRCUIT FUNCTION
HEATED SEAT DRIVER
HEATED SEAT DRIVER
DRIVER HEATED SEAT SWITCH OUTPUT
GROUND
CAV
A
B
C
D
P87 16BK/OR
P88 16BR/BK
P7 18LB/BK
Z1 20BK
BLACK
DRIVER HEATED
SEAT CUSHION
D
A
C
B
CIRCUIT FUNCTION
LUMBAR FORWARD DRIVER
LUMBAR REARWARD DRIVER
CAV
1
2
P106 18DG/WT
P107 18OR/BK
BLACK
DRIVER LUMBAR
MOTOR
2 1
8W - 80 - 31 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08031
CIRCUIT FUNCTION
SENSOR GROUND
FRONT RISER POSITION SENSE
6 VOLT SENSOR SUPPLY
CAV
A
B
C
P28 20BR/RD
P26 20BR
P29 20BR/WT
BLACK
DRIVER POWER SEAT
FRONT RISER MOTOR SENSOR
A C
DRIVER POWER SEAT
HORIZONTAL MOTOR
BLACK
2 1
CIRCUIT FUNCTION
HORIZONTAL FORWARD DRIVER
HORIZONTAL FORWARD SWITCH SENSE
HORIZONTAL REARWARD DRIVER
HORIZONTAL REARWARD SWITCH SENSE
CAV
1
1
2
2
P115 16GY/LG*
P15 16YL/LB
P117 16RD/BR*
P17 16RD/LB
CIRCUIT FUNCTION
6 VOLT SENSOR SUPPLY
HORIZONTAL POSITION SENSE
SENSOR GROUND
CAV
A
B
C
P29 20BR/WT
P25 20VT/RD
P28 20BR/RD
BLACK
DRIVER POWER SEAT
HORIZONTAL MOTOR
SENSOR
C A
* WITH MEMORY SEATS
RED
DRIVER POWER SEAT
FRONT RISER MOTOR
1 2
CIRCUIT FUNCTION
FRONT RISER DOWN DRIVER
FRONT RISER DOWN SWITCH SENSE
FRONT RISER UP DRIVER
FRONT RISER UP SWITCH SENSE
CAV
1
2
P121 16RD/GY*
P21 16RD/LG
P119 16YL/RD*
P19 16YL/LG
CIRCUIT FUNCTION
LUMBAR REARWARD DRIVER
LUMBAR FORWARD DRIVER
SENSOR GROUND
LUMBAR POSITION SENSE
6 VOLT SENSOR SUPPLY
CAV
1
2
3
4
5
P106 16DG/WT
P107 16OR/BK
P28 20BR/RD
P103 20DB/WT
P29 20BR/WT
BLACK
DRIVER POWER SEAT
LUMBAR SENSOR/MOTOR
1 3
4 6
ZG-RHD 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08032
CIRCUIT FUNCTION
LUMBAR REARWARD SWITCH SENSE
LUMBAR FORWARD DRIVER
GROUND
FUSED B(+)
GROUND LUMBAR FORWARD SWITCH SENSE
LUMBAR FORWARD SWITCH SENSE
LUMBAR REWARD DRIVER
CAV
1
1
2
3
4
5
5
P104 20YL/RD*
P107 18OR/BK
Z1 18BK
F35 18RD
Z1 18BK
P105 20LG/DB*
P106 18DG/WT
BLACK
DRIVER POWER SEAT
LUMBAR SWITCH
1 2
4 5
3
* WITH MEMORY SEATS
CIRCUIT FUNCTION
REAR RISER DOWN DRIVER
REAR RISER DOWN SWITCH SENSE
REAR RISER UP DRIVER
REAR RISER UP SWITCH SENSE
CAV
1
2
P113 16RD/BK*
P13 16RD/WT
P111 16YL/DB*
P11 16YL/WT
RED
DRIVER POWER SEAT
REAR RISER MOTOR
1 2
CIRCUIT FUNCTION
SENSOR GROUND
REAR RISER POSITION SENSE
6 VOLT SENSOR SUPPLY
CAV
A
B
C
P28 20BR/RD
P27 20LB/RD
P29 20BR/WT
BLACK
DRIVER POWER SEAT
REAR RISER MOTOR SENSOR
C A
CIRCUIT FUNCTION
RECLINER FORWARD DRIVER
RECLINER DOWN DRIVER
RECLINER REARWARD DRIVER
RECLINER DOWN DRIVER
CAV
A
A
B
B
P41 16GY/WT*
P41 16GY/WT
P43 16GY/LB*
P43 16GY/LB
BLACK
DRIVER POWER SEAT
RECLINER MOTOR
A B
8W - 80 - 33 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08033
CIRCUIT FUNCTION
6 VOLT SENSOR SUPPLY
HORIZONTAL POSITION SENSE
SENSOR GROUND
CAV
A
B
C
P29 20BR/WT
P47 20LB
P28 20BR/RD
BLACK
DRIVER POWER SEAT
RECLINER MOTOR
SENSOR
C A
CIRCUIT FUNCTION
GROUND
RECLINER UP SWITCH SENSE
RECLINER UP DRIVER
HORIZONTAL REARWARD SWITCH SENSE
HORIZONTAL REARWARD SWITCH SENSE
RECLINER DOWN SWITCH SENSE
RECLINER DOWN DRIVER
FUSED B(+)
HORIZONTAL FORWARD SWITCH SENSE
HORIZONTAL FORWARD SWITCH SENSE
FRONT RISER UP SWITCH SENSE
FRONT RISER UP SWITCH SENSE
REAR RISER UP SWITCH SENSE
REAR RISER UP SWITCH SENSE
REAR RISER DOWN SWITCH SENSE
REAR RISER DOWN SWITCH SENSE
FRONT RISER DOWN SWITCH SENSE
FRONT RISER DOWN SWITCH SENSE
CAV
1
2
2
3
3
4
4
5
6
6
7
7
8
8
9
9
10
10
Z1 16BK
P40 18GY/LB*
P43 16GY/LB
P17 18RD/LB*
P17 16RD/LB
P48 18GY/WT*
P41 16GY/WT
F35 16RD
P15 18YL/LB*
P15 16YL/LB
P19 18YL/LG*
P19 16YL/LG
P11 18YL/WT*
P11 16YL/WT
P13 18RD/WT*
P13 16RD/WT
P21 18RD/LG*
P21 16RD/LG
DRIVER POWER SEAT
SWITCH
GREEN
5
10
1
6
CIRCUIT
-
-
-
FUNCTION
-
-
-
FUSED IGNITION SWITCH OUTPUT
FUSED B(+)
HEATED SEAT DRIVER
GROUND
DRIVER HEATED SEAT SWITCH OUTPUT
CAV
1
2
3
4
5
6
7
8
F87 18PK/DG
F35 16RD
P87 16BK/OR
Z1 16BK
P7 18LB/BK
DRIVER SEAT HEATER
CONTROL MODULE
1
4
3
8
BLACK
* WITH MEMORY SEATS
ZG-RHD 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08034
2 1
DRIVER SIDE
AIRBAG
YELLOW
CIRCUIT FUNCTION
DRIVER AIR BAG LINE 2
DRIVER AIR BAG LINE 1
CAV
1
2
R45 18DG/LB
R43 18BK/LB
CIRCUIT FUNCTION
IGNITION SWITCH OUTPUT (START/RUN)
EVAPORATIVE EMISSION SOLENOID CONTROL
CAV
1
2
F99 20OR
K52 18PK/BK
1
DUTY CYCLE
EVAP/PURGE SOLENOID
BLACK
2
CIRCUIT FUNCTION
FUSED IGNITION SWITCH OUTPUT
EXHAUST GAS RCIRCULATION SOLENOID
GROUND
CAV
1
2
4
A142 16DG/OR
K35 16GY/YL
Z1 18BK
EGR SOLENOID
(DIESEL)
CIRCUIT FUNCTION
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
SENSOR GROUND
SECONDARY ENGINE COOLANT TEMP SENSOR
CAV
A
B
C
K2 20TN/BK
K4 20BK/LB
K222 20TN/RD
ENGINE COOLANT
TEMPERATURE SENSOR
(DIESEL)
** DIESEL
2
1
3
4
A B
C
CIRCUIT FUNCTION
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
SENSOR GROUND
CAV
1
2
K2 16TN/BK
K4 16BK/LB
ENGINE COOLANT
TEMPERATURE SENSOR
(WITH 4.OL ENG)
CIRCUIT FUNCTION
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
SENSOR GROUND
CAV
1
2
K2 16TN/BK
K4 16BK/LB
ENGINE COOLANT
TEMPERATURE SENSOR
(WITH 5.2L ENG)
BLACK
2
1
BLACK
1 2
8W - 80 - 35 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08035
* GAS
** DIESEL
CIRCUIT FUNCTION
B(+)
B(+)
ENGINE STARTER MOTOR RELAY OUTPUT
ENGINE STARTER MOTOR RELAY OUTPUT
CAV
1
1
2
2
A0 6RD
A0 2RD**
T40 12LG/BK
T40 14LG/BK**
ENGINE STARTER MOTOR
BLACK
1
2
CIRCUIT
-
FUNCTION
-
FUSED IGNITION SWITCH OUTPUT (START/RUN)
VAPOR CANISTER SOLENOID DRIVER
VAPOR CANISTER PUMP SWITCH DRIVER
CAV
1
2
3
4
F99 20OR
J95 18DG/RD
J96 18VT/RD
BLACK
EVAPORATIVE
SYSTEM
LEAK DETECTION
PUMP
4 1
CIRCUIT FUNCTION
GROUND
TRAILER TOW OUTPUT
PARK LAMP RELAY OUTPUT
FUSED B(+)
LEFT TURN SIGNAL
RIGHT TURN SIGNAL
BACK-UP LAMP SWITCH OUTPUT
CAV
1
2
3
4
5
6
7
Z1 12BK
B40 12LB
L90 18DB/RD
F70 18PK/BK
L61 18LG
L60 18TN
L10 18BR/LG
7
4
6
2
3
1
5
FACTORY TRAILER
TOW CONNECTOR
BLACK
BLACK
3 1
FLOOR CONSOLE
LAMPS
CIRCUIT
-
FUNCTION
-
GROUND
PANEL LAMP DRIVER
CAV
1
2
3
Z1 20BK
E2 18OR
CIRCUIT FUNCTION
-
-
POWER GROUND
GROUND
TRANS TEMP LAMP DRIVER
CAV
1
1
2
3
4
Z12 20BK/TN*
Z1 20BK**
T106 20GY/OR
G28 20LG/OR
T107 20BK/RD
BLACK
1
4 3
2
FOUR WHEEL DRIVE
SWITCH
8W - 80 - 36 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08036
CIRCUIT FUNCTION
SLEEVE POSITION SENSOR (-)
CONT SLEEVE POSITION SENSOR
SLEEVE POSITION SENSOR (+)
SENSOR GROUND
FUEL TIMING SHUTOFF SOLENOID
SHUTOFF FEED
FUEL TEMP SENSOR SIGNAL
FUEL QUANTITY ACTUATOR GROUND
AUTO SHUTDOWN RELAY OUTPUT
AUTO SHUTDOWN RELAY OUTPUT
CAV
1
2
3
4
5
6
7
8
9
10
K134 20LB/BK
K57 20LG/OR
K135 20WT/BK
K4 20BK/LB
K238 16VT
K153 20OR
K156 20GY
K140 14TN/WT
A142 14DG/OR
A142 16DG/OR
FUEL PUMP MODULE
(DIESEL)
CIRCUIT FUNCTION
FUEL PUMP RELAY OUTPUT
LOW
SENSOR RETURN
GROUND
CAV
1
3
4
6
A64 16DG/WT
G40 20LB/BK
K167 20BR/YL
Z1 16BK
FUEL PUMP MODULE
(GAS)
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL TIMING SHUTOFF SOLENOID
SHUTOFF (+)
CAV
1
2
3
A142 16DG/BK
D238 16VT
K153 20OR
FUEL TIMING SOLENOID
(DIESEL)
CIRCUIT FUNCTION
ELECTRIC PUMP FEED
GROUND
CAV
1
2
A64 14OR/DB
Z1 14BK
FUEL HEATER
(DIESEL)
5
1
6
10
BLACK
4
1
6
3
2 1
1
2
3
BLACK
BLACK
BLACK
4
1
6
3
CIRCUIT FUNCTION
FUEL PUMP RELAY OUTPUT
LOW
SENSOR RETURN
GROUND
CAV
1
3
4
6
A64 16DG/WT
G40 20LB/BK
K167 20BR/YL
Z1 16BK
FUEL SENDER UNIT
(DIESEL)
BLACK
8W - 80 - 37 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08037
CIRCUIT FUNCTION
G SWITCH GROUND
G SWITCH NO. 1 SENSE
G SWITCH NO. 2 SENSE
CAV
1
2
3
B43 20PK/OR
B41 20YL/VT
B42 20TN/WT
G-SWITCH
CIRCUIT
-
FUNCTION
-
AUTOMATIC SHUT DOWN RELAY OUTPUT
GENERATOR FIELD DRIVER
CAV
1
2
3
A142 16DG/OR
K20 18DG/YL
GENERATOR
(DIESEL)
CIRCUIT
-
FUNCTION
-
GROUND
AUTOMATIC SHUT DOWN RELAY OUTPUT
GENERATOR FIELD DRIVER
CAV
1
2
3
4
Z0 8BK
K72 18DG/VT
K20 18DG
GENERATOR
(GAS)
CIRCUIT FUNCTION
BATTERY POSITIVE
GLOW PLUG RELAY CONTROL SENSE
FUSED IGNITION SWITCH OUTPUT
GLOW PLUG RELAY CONTROL
CAV
1
2
3
4
A0 10RD
K152 16WT
A142 16DG/OR
K154 10GY
GLOW PLUG RELAY
(DIESEL)
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
1
2
M1 20PK
Z1 20BK
2
GLOVE BOX LAMP
BLACK
1
1 3
BLACK
1
3 2
BLACK
1
2
3
4
1
2
3
4
BLACK
1
2
3
4
5
6
7
8
8W - 80 - 38 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08038
CIRCUIT
-
-
-
FUNCTION
-
-
-
ENGINE COOLANT LEVEL SWITCH SENSE
FUSED B(+)
GROUND
TURN SIGNAL
REAR LAMP OUT INDICATOR DRIVER
CCD BUS (+)
CCD BUS (-)
PANEL LAMP DRIVER
PARK LAMP RELAY OUTPUT
WASHER FLUID LEVEL SENSE
4-WHEEL DRIVE PART TIME LAMP
4-WHEEL DRIVE FULL TIME LAMP
FUSED IGNITION SWITCH OUTPUT (RUN)
4-WHEEL DRIVE PART TIME LAMP
ALL TIME FRONT WHEELS
2-WHEEL DRIVE OR REAR WHEELS IN ALL TIME
GROUND
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
G18 20PK/BK
F60 20RD/WT
Z2 20BK/OR
L5 18OR/BK
G46 20BK/LB
D1 18VT/BR
D2 18WT/BK
E2 20OR
L90 20DB/RD
G29 2OBK/TN
107 20BK/RD
T106 20GY/OR
F83 18YL/DG
T19 20YL/BK
G42 20LB/RD
G28 20LG/OR
Z1 20BK
GRAPHIC DISPLAY
MODULE OR VEHICLE
INFORMATION CENTER
BLACK
10 1
20 11
CIRCUIT FUNCTION
GROUND HD/LP LEVELING
POSITION F
POSITION C
POSITION D
FUSED IGN. SWITCH OUTPUT
POSITION A
POSITION B
POSITION E
CAV
1
2
3
4
5
6
7
8
Z1 20BK
L106 20YL
L103 20LB
L104 20LG
F83 18YL/DG
L101 20RD
L102 20WT
L105 20PK
HEADLAMP LEVELING
SWITCH
EXPORT
BLACK
8W - 80 - 39 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08039
CIRCUIT
-
-
-
FUNCTION
-
-
-
PANEL LAMP DRIVER
GROUND
SWITCHED COURTESY LAMP FEED
FOG LAMP RELAY OUTPUT
GROUND
FOG LAMP SWITCH OUTPUT
COIL DRIVER #6
PANEL LAMP DIMMER SWITCH SIGNAL
FUSED B(+)
LOW HEADLAMP SWITCH SENSE
AUTO HEADLAMP SWITCH SENSE
PARK LAMP FEED
PARK LAMP RELAY OUTPUT
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
E2 20OR
Z1 16BK
M11 20PK/LB
L39 20LB
Z1 16BK
L35 20BR/WT
L96 20LG/RD
707 20BK/WT
A6 14RD/LB
F34 16TN/BK
L24 20LB/RD
366 16PK/OR
L90 20DB/RD
HEADLAMP SWITCH
9
BLACK
1
16
8
CIRCUIT
-
-
FUNCTION
-
-
FUSED B(+)
BLOWER MOTOR DRIVER
HIGH BLOWER MOTOR RELAY CONTROL
FUSED B(+)
CAV
1
2
3
4
5
6
A19 14RD/VT
C42 12BR/RD
C41 20BR
A19 12DG/RD
HIGH SPEED BLOWER
MOTOR RELAY
BLACK
1
2 3
4
5
CIRCUIT FUNCTION
HORN RELAY OUTPUT
GROUND
CAV
1
2
X2 16DG/YL
Z1 16BK
HORN NO.1
BLACK
1 2
CIRCUIT FUNCTION
HORN RELAY OUTPUT
GROUND
CAV
1
2
X2 16DG/YL
Z1 16BK
HORN NO.2
BLACK
1 2
8W - 80 - 40 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08040
CIRCUIT FUNCTION
IDLE AIR CONTROL NO. 1 DRIVER
IDLE AIR CONTROL NO. 3 DRIVER
IDLE AIR CONTROL NO. 4 DRIVER
IDLE AIR CONTROL NO. 2 DRIVER
CAV
1
2
3
4
K39 16GY/RD
K40 16BR/WT
K59 16VT/BK
K60 16YL/BK
IDLE AIR
CONTROL MOTOR
(5.2L V-8)
BLACK
4 1
CIRCUIT FUNCTION
IDLE AIR CONTROL NO. 2 DRIVER
IDLE AIR CONTROL NO. 4 DRIVER
IDLE AIR CONTROL NO. 3 DRIVER
IDLE AIR CONTROL NO. 1 DRIVER
CAV
1
2
3
4
K60 16YL/BK
K59 16VT/BK
K40 16BR/WT
K39 16GY/RD
BLACK
IDLE AIR
CONTROL MOTOR
(4.0L I-6)
4 1
CIRCUIT FUNCTION
IGNITION COIL NO. 1 DRIVER
AUTOMATIC SHUT DOWN RELAY OUTPUT
CAV
1
2
K19 18GY/WT
A142 18DG/OR
IGNITION COIL
1
BLACK
2
CIRCUIT FUNCTION
IGNITION SWITCH OUTPUT (START)
IGNITION SWITCH OUTPUT (START/RUN)
RED BRAKE WARNING LAMP DRIVER
FUSED B(+)
IGNITION SWITCH OUTPUT (RUN)
IGNITION SWITCH OUTPUT (ACC/RUN)
FUSED B(+)
CAV
1
2
3
4
5
6
7
A41 14YL
A21 12DB/GY
G9 18GY/BK
A1 12RD/WT
A22 12BK/OR
A31 12RD/BK
A1 12RD/WT
IGNITION SWITCH
BLACK
7 1
A
CIRCUIT FUNCTION
IN-CAR TEMPERATURE SENSOR SIGNAL
SENSOR GROUND
CAV
A
B
C10 20RD/TN
D41 20LG/WT
IN-CAR TEMPERATURE
SENSOR
BLACK
B
8W - 80 - 41 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08041
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
INJECTOR NO.1 DRIVER
CAV
1
2
A142 18DG/OR
K11 18WT/DB
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
INJECTOR NO. 2 DRIVER
CAV
1
2
A142 18DG/OR
K12 18TN
GRAY
2
FUEL INJECTOR
NO.1
1
GRAY
2
FUEL INJECTOR
NO.2
1
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
INJECTOR NO. 3 DRIVER
CAV
1
2
A142 18DG/OR
K13 18YL/WT
GRAY
2
FUEL INJECTOR
NO.3
1
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
INJECTOR NO. 4 DRIVER
CAV
1
2
A142 18DG/OR
K14 18LB/BR
GRAY
2
FUEL INJECTOR
NO.4
1
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
INJECTOR NO. 5 DRIVER
CAV
1
2
A142 18DG/OR
K38 18GY
GRAY
2
FUEL INJECTOR
NO.5
1
8W - 80 - 42 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08042
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
INJECTOR NO. 6 DRIVER
CAV
1
2
A142 18DG/OR
K58 18BR/YL
GRAY
2
FUEL INJECTOR
NO.6
1
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
INJECTOR NO. 7 DRIVER
CAV
1
2
A142 18DG/OR
K17 18DB/WT
GRAY
2
FUEL INJECTOR
NO.7
(WITH 5.2L ENG)
1
12
7
8
3
1 2
JUNCTION BLOCK - C1
BLUE
CIRCUIT
-
-
-
FUNCTION
-
-
-
FUSED B(+)
BACK-UP LAMP SWITCH OUTPUT
FOG LAMP SWITCH OUTPUT
FUSED B(+)
4-WHEEL DRIVE PART TIME LAMP
FUSED B(+)
PARK LAMP SWITCH OUTPUT
FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
M1 18PK
L10 18BR/LG
L39 18LB
F62 18RD
T107 20BK/RD
A6 14RD/LB
L90 18DB/RD
F12 20DB/WT
F86 18LG/RD
CIRCUIT FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
INJECTOR NO. 8 DRIVER
CAV
1
2
A142 18DG/OR
K18 18DB/YL
GRAY
2
FUEL INJECTOR
NO.8
(WITH 5.2L ENG)
1
CIRCUIT FUNCTION
GROUND
GROUND
FUSED B(+)
ABS WARNING LAMP DRIVER
FUSED IGNITION SWITCH OUTPUT (START/RUN)
LEFT TURN SIGNAL INDICATOR LAMP
RIGHT TURN SIGNAL INDICATOR LAMP
CCD BUS (+)
CCD BUS (-)
PANEL LAMP DRIVER
CAV
1
2
3
4
5
6
7
8
9
10
Z1 20BK
Z2 20BK/OR
F75 18VT
205 20WT/VT
F87 20BK/WT
L65 18LG/DB
L64 18TN/DB
D1 18VT/BR
D2 18WT/BK
E2 20OR
BLACK
5 1
10 6
INSTRUMENT
CLUSTER
CIRCUIT FUNCTION
INTAKE AIR TEMPERATURE SENSOR SIGNAL
SENSOR GROUND
CAV
1
2
K21 16BK/RD
K4 16BK/LB
GRAY
INTAKE AIR
TEMPERATURE SENSOR
1 2
8W - 80 - 43 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08043
JUNCTION BLOCK - C3
CIRCUIT
-
-
-
-
FUNCTION
-
-
-
-
HORN RELAY CONTROL
2-WHEEL DRIVE LAMP/LOW RANGE
FOG LAMP RELAY OUTPUT
FUSED B(+)
FUSED B(+)
PARK LAMP SWITCH OUTPUT
TURN SIGNAL SWITCH OUTPUT
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
X4 20GY/OR
G28 20LG/OR
L39 18LB
F62 18RD
A6 14RD/LB
L90 18DB/RD
L64 18TN/DB
F12 20DB/WT
JUNCTION BLOCK - C4
7
3
1
10
6
2
NATURAL
CIRCUIT
-
FUNCTION
-
RIGHT TURN SIGNAL INDICATOR LAMP
4-WHEEL DRIVE PART TIME LAMP
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
RIGHT TURN SIGNAL INDICATOR LAMP
4-WHEEL DRIVE PART TIME LAMP
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
FUSED B(+)
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
L64 18TN/DB
107 20BK/RD
F30 18RD/DB
A31 18RD/BK
L64 18TN/DB
107 20BK/RD
F86 16LG/BK*
F86 16LG/BK
F75 18VT
F75 18VT
* WITH POWER SUNROOF
7
3
1
10
6
2
JUNCTION BLOCK - C5
RED
CIRCUIT
-
-
FUNCTION
-
-
TURN SIGNAL
2-WHEEL DRIVE OR REAR WHEEL IN ALL TIME
GROUND
RADIO 12 VOLT OUTPUT
ALL TIME FRONT WHEELS
AUTO HEADLAMP RELAY OUTPUT
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (RUN)
CAV
1
2
3
4
5
6
7
8
9
10
L5 18OR/BK
G28 20LG/OR
Z1 18BK
X60 20DG/RD
G28 20LG/OR
F34 16TN/BK
A6 14RD/LB
A22 12BK/OR
12
7
8
3
1 2
BLUE
2
4
1
3
JUNCTION BLOCK - C2
GRAY
CIRCUIT FUNCTION
IGNITION SWITCH OUTPUT (START/RUN)
FUSED B(+)
FUSED B(+)
FUSED B(+)
CAV
1
2
3
4
A21 12DB/GY
A7 12YL/RD
A900 12OR/YL
A250 10RD
8W - 80 - 44 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08044
JUNCTION BLOCK - C6
3
1
4
2
BLACK
CIRCUIT FUNCTION
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
FUSED IGNITION SWITCH OUTPUT (START/RUN)
REAR WINDOW DEFOGGER RELAY OUTPUT
FUSED B(+)
CAV
1
2
3
4
A31 12RD/BK
A21 12DB/GY
C15 12BK/WT
F61 16WT/OR
JUNCTION BLOCK - C7
8
3
12
7
1 2
GRAY
CIRCUIT
-
FUNCTION
-
-
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
FLASH TO PASS
FOG LAMP RELAY CONTROL
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
HAZARD SIGNAL
REAR FOG LAMP
FOG LAMP RELAY OUTPUT
GROUND
FOG LAMP RELAY CONTROL
HORN RELAY CONTROL
CAV
1
2
3
4
5
6
7
8
9
10
11
12
X12 18RD/GY
L11 16LG/BK
L95 18DG/YL
A31 18RD/BK
L12 18VT/TN
L36 18LG
L96 20LG/RD
L39 20LB
Z1 18BK
L95 18DG/YL
X4 20GY/OR
CIRCUIT
-
FUNCTION
-
FUSED IGNITION SWITCH OUTPUT (RUN)
COURTESY LAMP RELAY OUTPUT
FUSED B(+)
PARK LAMP SWITCH OUTPUT
PARK LAMP SWITCH OUTPUT
FUSED B(+)
COURTESY LAMP RELAY OUTPUT
MUX COURTESY LAMP DRIVER
PARK LAMP SWITCH OUTPUT
FUSED B(+)
COURTESY LAMP RELAY OUTPUT
CAV
1
2
3
4
5
6
7
8
9
10
11
12
F83 18YL/DG
M2 20YL
M1 20PK
L90 18DB/RD
L90 20DB/RD
M1 20PK
M2 20YL
M1 20PK
L90 20DB/RD
M1 20PK
M2 20YL
JUNCTION BLOCK - C8
8
3
12
7
1 2
YELLOW
8W - 80 - 45 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08045
8
3
1
12
7
2
JUNCTION BLOCK - C9
LIGHT
GRAY
CIRCUIT
-
-
-
FUNCTION
-
-
-
REAR WINDOW DEFOGGER LAMP DRIVER
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (START/RUN)
FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED B(+)
PARK LAMP FEED
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
C16 20LB/YL
F38 18OR
F71 20DG/PK*
F60 20RD/WT
F87 20BK/WT
F71 20PK/DG*
F60 20RD/WT
366 16PK/OR
F60 20WT/RD*
8
3
1
12
7
2
JUNCTION BLOCK - C10
GREEN
CIRCUIT
-
-
FUNCTION
-
-
FOG LAMP RELAY CONTROL
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
COURTESY LAMP RELAY CONTROL
HORN RELAY CONTROL
REAR WINDOW DEFOGGER RELAY CONTROL
PARK LAMP RELAY CONTROL
PARK LAMP SWITCH OUTPUT
AUTO HEADLAMP RELAY CONTROL
CAV
1
2
3
4
5
6
7
8
9
10
11
12
L95 20DG/YL
V23 18BR/PK
L16 18RD/LG
V23 20BR/PK
M112 20BR/LG
X4 20GY/OR
C14 20WT/RD
L79 20TN
L90 20DB/RD
714 20BK/OR
CIRCUIT FUNCTION
POWER ANTENNA UP CONTROL
POWER ANTENNA DOWN CONTROL
POWER ANTENNA DRIVER
CAV
1
2
3
X17 20DG
X14 20WT
X16 20GY
JUNCTION BLOCK - C11
BLACK
1
3
2
* AUTOMATIC TEMP CONTROL
2
7
12
3
8
1
JUNCTION BLOCK
BODY CONNECTOR - C13
NATURAL
CIRCUIT
-
-
-
-
-
FUNCTION
-
-
-
-
-
FUSED IGNITION SWITCH OUTPUT (RUN)
PARK LAMP RELAY OUTPUT
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED IGNITION SWITCH OUTPUT (START/RUN)
FUSED B(+)
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
F20 18WT
L90 18DB/RD
M1 20PK
F12 20DB/WT
F87 20WT/PK
F75 14VT
F35 16RD
8W - 80 - 46 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08046
BLACK
1
3 6
7 10
2
JUNCTION BLOCK
BODY CONNECTOR - C14
CIRCUIT
-
-
FUNCTION
-
-
BACK-UP LAMP SWITCH OUTPUT
FUSED IGNITION SWITCH OUTPUT (START/RUN)
COURTESY LAMP RELAY OUTPUT
RADIO 12 VOLT OUTPUT
FUSED B(+)
FUSED B(+)
FUSED B(+)
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
L10 18BR/LG
G5 18DB/WT
M2 20YL
X60 18DG/RD
F81 10TN
F70 14PK/BK
F81 12TN
F35 16RD
CIRCUIT
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
GROUND
FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED IGNITION SWITCH OUTPUT (RUN)
BACK-UP LAMP SWITCH OUTPUT
FUSED B(+)
COURTESY LAMP RELAY OUTPUT
CAV
1
2
3
3
4
5
6
7
8
9
10
11
12
Z1 16BK
F83 20YL/DG*
F83 20BK/VT
L10 20BK/RD
M1 20PK
M2 20YL
8
3
1 2
7
12
JUNCTION BLOCK - C15
(OVERHEAD CONSOLE)
BLACK
CIRCUIT FUNCTION
GROUND
KEY-IN IGNITION SWITCH SENSE
COURTESY LAMP RELAY OUTPUT
FUSED B(+)
CAV
1
2
3
4
Z1 20BK
G26 20LB
M2 20YL
M1 20PK
GRAY
KEY-IN SWITCH/
HALO LAMP
1 4
* WITH OVERHEAD CONSOLE
8W - 80 - 47 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08047
CIRCUIT
-
FUNCTION
-
NOT USED
NOT USED
STOP LAMP SWITCH OUTPUT
PARK LAMP RELAY OUTPUT
PARK LAMP RELAY OUTPUT
PARK LAMP SWITCH OUTPUT
PARK LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT
GROUND
CAV
1
2
3
4
5
6
7
8
9
10
L36 18LG/OR
L36 18LG/OR
L50 18WT/TN
L90 18DB/RD*
L90 18DB/RD
L22 18LB
L21 18LB/WT
L74 18PK/BK
L73 18PK/WT
L87 18DG/WT
Z1 18BK
10
5
6
1
BLACK
LAMP OUTAGE MODULE - C1
LAMP OUTAGE MODULE - C2
CIRCUIT FUNCTION
NOT USED
STOP LAMP SWITCH OUTPUT
PARK LAMP RELAY OUTPUT
PARK LAMP RELAY OUTPUT
PARK LAMP RELAY OUTPUT
PARK LAMP RELAY OUTPUT
PARK LAMP RELAY OUTPUT
STOP LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT
REAR LAMP OUT INDICATOR DRIVER
FUSED IGNITION SWITCH OUTPUT (START/RUN)
CAV
1
2
3
4
5
6
7
8
9
10
L36 18LG/OR
L50 18WT/TN
L90 18DB/RD
L90 18DB/RD
L90 18DB/RD
L90 18DB/RD
L90 18DB/RD
L50 18WT/TN
L50 18WT/TN
L50 18WT/TN
G46 20LB/BK
F87 18WT/PK
6
1
10
5
BLACK
* WITH AFTERMARKET TRAILER
TOW OR FACTORY TRAILER TOW
CIRCUIT FUNCTION
LEFT IMPACT SENSOR LINE 1
LEFT IMPACT SENSOR LINE 2
CAV
1
2
R47 18DB/LB
R49 18LB
LEFT AIRBAG
SENSOR
BLACK
1 2
8W - 80 - 48 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08048
CIRCUIT FUNCTION
BACK-UP LAMP SWITCH OUTPUT
GROUND
CAV
A
G
L10 18BR/LG
Z1 18BK
BLACK
LEFT BACK-UP LAMP
A
G
CIRCUIT FUNCTION
FUSED B(+)
COURTESY LAMP RELAY OUTPUT
CAV
A
B
M1 20PK
M2 20YL
LEFT COURTESY
LAMP
BLACK
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
1
2
M1 20PK
Z1 20BK
BLACK
1 2
LEFT DOOR
COURTESY LAMP
CIRCUIT FUNCTION
GROUND
FOG LAMP RELAY SWITCH OUTPUT
CAV
1
2
Z1 18BK
L39 18LB
LEFT FOG LAMP
BLACK
2 1
CIRCUIT FUNCTION
VTSS DISARM SENSE
GROUND
CAV
1
2
G71 20VT/YL
Z1 20BK
BLACK
2 1
LEFT FRONT
CYLINDER LOCK SWITCH
8W - 80 - 49 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08049
CIRCUIT FUNCTION
LEFT FRONT DOOR UNLOCK DRIVER
LEFT FRONT DOOR LOCK DRIVER
CAV
1
2
P34 18PK/BK
P35 18OR/VT
BLACK
2 1
LEFT FRONT DOOR
LOCK MOTOR
CIRCUIT FUNCTION
LEFT FRONT (+)
LEFT FRONT (-)
CAV
A
B
X53 20DG
X55 20BR/RD
B
LEFT FRONT
DOOR SPEAKER
BLACK
A
CIRCUIT FUNCTION
LEFT FRONT WINDOW DRIVER (UP)
LEFT FRONT WINDOW DRIVER (DOWN)
CAV
1
2
Q11 16LB
Q21 16WT
BLACK
LEFT FRONT POWER
WINDOW MOTOR
2 1
CIRCUIT FUNCTION
PARK LAMP RELAY OUTPUT
GROUND
CAV
A
B
L90 18DB/RD
Z1 18BK
WHITE
LEFT FRONT PARK LAMP
B A
CIRCUIT FUNCTION
PARK LAMP RELAY OUTPUT
TURN SIGNAL SWITCH OUTPUT
CAV
A
B
L90 18DB/RD
L64 18TN/DB
GRAY
LEFT FRONT SIDE MARKER LAMP
B A
8W - 80 - 50 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08050
BLACK
LEFT FRONT TURN
SIGNAL LAMP
A
G
CIRCUIT FUNCTION
TURN SIGNAL SWITCH OUTPUT
GROUND
CAV
A
G
L64 18TN/DB
Z1 18BK
CIRCUIT FUNCTION
LEFT FRONT WHEEL SPEED SENSOR (-)
LEFT FRONT WHEEL SPEED SENSOR (+)
CAV
1
2
B8 20RD/DB
B9 20RD
LEFT FRONT
WHEEL SPEED SENSOR
BLACK
2 1
CIRCUIT FUNCTION
GROUND
DIMMER SWITCH LOW BEAM OUTPUT
DIMMER SWITCH HIGH BEAM OUTPUT
CAV
1
2
3
Z1 16BK
L4 16VT/OR
L3 16RD/OR
LEFT HEADLAMP
BLACK
1
2
3
CIRCUIT FUNCTION
AMPLIFIED LEFT FRONT (+)
AMPLIFIED LEFT FRONT (-)
CAV
A
B
X87 20LG/RD
X85 20LG/BK
LEFT INSTRUMENT
PANEL SPEAKER
BLACK
A B
CIRCUIT FUNCTION
POSITION 4
POSITION 3
POSITION 2
POSITION 5
POSITION 6
POSITION 1
CAV
1
2
3
4
5
6
L104 20LG
L103 20LB
L102 20WT
L105 20PK
L106 20YL
L101 20RD
LEFT HEADLAMP LEVELING
MOTOR
EXPORT
1
4
3
6
8W - 80 - 51 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08051
CIRCUIT FUNCTION
PARK LAMP RELAY OUTPUT
GROUND
CAV
1
2
L90 20DB/RD
Z1 20BK
NATURAL
LEFT LICENSE LAMP
1 2
CIRCUIT FUNCTION
PARK LAMP RELAY
GROUND
CAV
1
2
L90 18DB/RD
Z1 18BK
LEFT PARK LAMP
CIRCUIT FUNCTION
DOOR UNLOCK DRIVER
DOOR LOCK DRIVER
CAV
1
2
P34 18PK/BK
P2 18BK/WT
LEFT REAR DOOR
LOCK MOTOR
BLACK
1 2
CIRCUIT FUNCTION
LEFT REAR (+)
LEFT REAR (-)
CAV
A
B
X52 20DB/WT
X58 20DB/OR
B
LEFT REAR
DOOR SPEAKER
BLACK
A
CIRCUIT FUNCTION
LEFT FRONT T.S. FEED
PARK LAMP SWITCH OUTPUT
GROUND
CAV
1
2
3
L65 18LG/DB
L90 18DB/RD
Z1 18BK
LEFT PARK TURN
SIGNAL MARKER
1 2
CIRCUIT FUNCTION
REAR FOG LAMP
GROUND
CAV
A
B
L36 18LG/BK
Z1 18BK
LEFT REAR
FOG LAMP
1 2
3
BLACK
8W - 80 - 52 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08052
CIRCUIT FUNCTION
LEFT REAR WINDOW DRIVER (UP)
LEFT REAR WINDOW DRIVER (UP)
LEFT REAR DOOR SWITCH ILLUMINATION
LEFT REAR WINDOW DRIVER (DOWN)
LEFT REAR WINDOW DRIVER (DOWN)
GROUND
CAV
1
2
3
4
5
6
Q18 16GY/BK
Q12 16BR
E20 20OR/DG
Q28 16DG/WT
Q22 16VT
Z1 16BK
1
4
3
6
LEFT REAR POWER
WINDOW SWITCH
BLUE
CIRCUIT FUNCTION
GROUND
PARK LAMP SWITCH OUTPUT
CAV
1
2
Z1 18BK
L22 18LB
NATURAL
LEFT REAR SIDE MARKER LAMP
1 2
CIRCUIT FUNCTION
GROUND
LEFT FRONT TURN SIGNAL FEED
CAV
1
2
Z1 18BK
L65 18LG/DB
LEFT SIDE REPEATER
CIRCUIT FUNCTION
TURN SIGNAL SWITCH OUTPUT
GROUND
CAV
A
G
L60 18TN
Z1 18BK
BLACK
LEFT REAR TURN
SIGNAL LAMP
A
G
CIRCUIT FUNCTION
LEFT REAR WHEEL SPEED SENSOR (-)
LEFT REAR WHEEL SPEED SENSOR (+)
CAV
A
B
B3 20LG/DB
B4 20LG
LEFT REAR WHEEL
SPEED SENSOR
B A
BLACK
CIRCUIT FUNCTION
LEFT REAR WINDOW DRIVER (UP)
LEFT REAR WINDOW DRIVER (DOWN)
CAV
1
2
Q12 16BR
Q22 16VT
2
LEFT REAR POWER
WINDOW MOTOR
BLACK
1
1
2
8W - 80 - 53 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08053
CIRCUIT FUNCTION
STOP LAMP SWITCH OUTPUT
PARK LAMP SWITCH OUTPUT
GROUND
CAV
A
B
G
L74 18PK/BK
L21 18LB/WT
Z1 18BK
BLACK
B
A
G
LEFT TAIL/STOP LAMP
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
A
B
M1 20PK
Z1 20BK
A
LEFT VISOR/
VANITY MIRROR
BLACK
B
CIRCUIT
-
FUNCTION
-
GROUND
LIFTGATE AJAR SWITCH SENSE
CAV
1
2
3
Z1 20BK
G78 20TN/BK
1
LIFTGATE AJAR SWITCH
BLACK
3
CIRCUIT FUNCTION
VTSS DISARM SENSE
GROUND
CAV
1
2
G71 20VT/YL
Z1 20BK
1
LIFTGATE
CYLINDER LOCK SWITCH
BLACK
2
CIRCUIT FUNCTION
DOOR LOCK DRIVER
DOOR UNLOCK DRIVER
CAV
A
B
P2 16BK/WT
P34 16PK/BK
B
LIFTGATE LOCK MOTOR
BLACK
A
8W - 80 - 54 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08054
CIRCUIT
-
FUNCTION
-
GROUND
LIFTGLASS AJAR SWITCH SENSE
CAV
1
2
3
Z1 20BK
G78 20TN/BK
1
LIFTGLASS AJAR SWITCH
BLACK
3
CIRCUIT FUNCTION
FUSED B(+)
LIFTGLASS LIMIT SWITCH OUTPUT
CAV
A
B
F70 16PK/BK
P101 16OR/PK
A
LIFTGLASS LIMIT SWITCH
NATURAL
B
CIRCUIT FUNCTION
LIFTGLASS PUSH BUTTON OUTPUT
LIFTGLASS LIMIT SWITCH OUTPUT
CAV
1
2
P100 14OR/BR
P101 16OR/PK
1
LIFTGLASS PUSH BUTTON
BLACK
2
CIRCUIT FUNCTION
LIFTGLASS PUSH BUTTON OUTPUT
GROUND
CAV
1
2
P100 14OR/BR
Z1 14BK
2
LIFTGLASS RELEASE
SOLENOID
BLACK
1
CIRCUIT FUNCTION
SENSOR GROUND
MAP SENSOR SIGNAL
5 VOLT SUPPLY
CAV
1
2
3
K4 20BK/LB
K70 18RD/WT
K25 20WT/BK
MANIFOLD ABSOLUTE
PRESSURE SENSOR
BLACK
3 1
8W - 80 - 55 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08055
CIRCUIT FUNCTION
GROUND
SENSOR GROUND
FUSED (B+)
AIR FLOW METER SIGNAL
CAV
1
2
3
4
Z1 20BK
K4 20BK/LB
A142 18DG/OR
K155 20DB MASS AIR FLOW MODULE
CIRCUIT FUNCTION
POWER GROUND
TACHOMETER SIGNAL
WAIT TO START LAMP
FUEL QUANTITY ACTUATOR GROUND
FUEL QUANTITY ACTUATOR GROUND
CONT SLEEVE POS SENSE
CRANKSHAFT POSITION SENSOR
NEEDLE MOVE SENSOR (-)
NEEDLE MOVE SENSOR (+)
AIR FLOW METER SIGNAL
ENGINE COOLANT TEMPERATUR SENSOR SIGNAL
THROTTLE POSITION SENSOR SIGNAL
STOP LAMP SWITCH OUTPUT
AUTO SHUTDOWN RELAY OUTPUT
POWER GROUND
EGR SOLENOID CONTROL
FLT SIGNAL
COIL DRIVER #2
A/C COMPRESSOR CLUTCH RELAY CONTROL
SLEEVE POSITION SENSE
SENSOR GROUND
VEHICLE SPEED CONTROL SWITCH SIGNAL
A/C SWITCH SIGNAL
FUEL HEATER RELAY OUTPUT
AUTOMATIC SHUTDOWN RELAY CONTROL
VEHICLE SPEED SENSOR SIGNAL
SPEED CONTROL ON/OFF SWITCH SENSE
AUTO SHUT DOWN RELAY (+)
POWER GROUND
FUEL QUANTITY ACTUATOR GROUND
GLOW PLUG RELAY CONTROL SENSE
FUEL TIMING SHUTOFF SENSOR
SLEEVE POSITION SENSOR (+)
SHUTOFF FEED
PEDAL POSITION SENSOR
5 VOLT SUPPLY
SCI RECEIVE
FUEL TEMPERATURE SENSOR SIGNAL
LOW IDLE POSITION SWITCH
LEFT FRONT DECAY SOLENOID CONTROL
CAV
1
2
3
4
5
7
8
11
12
13
14
15
20
23
24
25
26
27
28
29
33
36
37
38
42
43
44
45
46
49
50
51
52
53
55
57
61
63
65
68
Z12 14BK/TN
G21 20GY/LB
K185 18OR/LB
K140 16TN/WT
K140 16TN/WT
K57 20LG/OR
K24 20LG/YL
K68 20LG/YL
K67 20BR/BK
K155 20DB
K2 20TN/BK
K22 20OR/DB
L50 18WT/TN
A142 14DG/OR
Z12 16BK/TN
K35 16GY/YL
K48 18OR/RD
K92 20PK
C13 16DB/RD
K134 20LB/BK
K4 20BK/LB
K95 20PK
C103 20DG
F99 20RD/OR
K900 20PK/BK
G7 20WT/OR
V32 20YL/RD
A142 16DG/OR
Z12 16BK/TN
K140 16TN/WT
K152 16WT
K238 16VT
K135 20WT/BK
K153 20OR
K255 20WT/DG
K6 20VT/WT
D83 20BK/PK
K156 20GY
K151 20WT
A142 16DG/OR
MSA CONTROLLER
(DIESEL)
1
2
22
23
68
48
4 1
(CAVITIES NOT SHOWN ARE NOT USED)
8W - 80 -56 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08056
CIRCUIT
-
FUNCTION
-
6 VOLT SENSOR SUPPLY
SENSOR GROUND
HORIZONTAL POSITION SENSE
FRONT RISER POSITION SENSE
REAR RISER POSITION SENSE
RECLINER POSITION SENSE
LUMBAR POSITION SENSE
FRONT RISER DOWN SWITCH SENSE
FRONT RISER UP SWITCH SENSE
REAR RISER DOWN SWITCH SENSE
REAR RISER UP SWITCH SENSE
HORIZONTAL FORWARD SWITCH SENSE
HORIZONTAL REARWARD SWITCH SENSE
RECLINER UP SWITCH SENSE
RECLINER DOWN SWITCH SENSE
LUMBAR FORWARD SWITCH SENSE
LUMBAR REARWARD SWITCH SENSE
CCD BUS (+)
CCD BUS (-)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
P29 20BR/WT
P28 20BR/RD
P25 20VT/RD
P26 20BR
P27 20LB/RD
P47 20LB
P103 20DB/WT
P21 18RD/LG
P19 18YL/LG
P13 18RD/WT
P11 18YL/WT
P15 18YL/LB
P17 18RD/LB
P40 18GY/LB
P48 18GY/WT
P105 20LG/DB
P104 20YL/RD
D1 20VT/BR
D2 20WT/BK
BLACK
MEMORY SEAT
MODULE - C1
1
11
10
20
CIRCUIT
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
GROUND
HORIZONTAL FORWARD DRIVER
HORIZONTAL REARWARD DRIVER
RECLINER REARWARD DRIVER
RECLINER FORWARD DRIVER
GROUND
LUMBAR REARWARD DRIVER
FUSED B(+)
REAR RISER DOWN DRIVER
REAR RISER UP DRIVER
FRONT RISER DOWN DRIVER
FRONT RISER UP DRIVER
FUSED B(+)
LUMBAR FORWARD DRIVER
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Z1 16BK
P115 16GY/LG
P117 16RD/BR
P43 16GY/LB
P41 16GY/WT
Z1 16BK
P106 16DG/WT
F35 16RD
P113 16RD/BK
P111 16YL/DB
P121 16RD/GY
P119 16YL/RD
F35 16RD
P107 16OR/BK
BLACK
MEMORY SEAT
MODULE - C2
1
10
9
20
8W - 80 - 57 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08057
CIRCUIT FUNCTION
FUSED IGNITION SWITCH OUTPUT (RUN)
GROUND
CCD BUS(+)
COURTESY LAMP RELAY OUTPUT
CCD BUS(-)
FUSED B(+)
CAV
1
2
3
4
5
6
F83 20YL/DG
Z1 20BK
D1 18VT/BR
M2 20YL
D2 18WT/BK
M1 20PK
MINI OVERHEAD
CONSOLE
RED
3
4
1
6
CIRCUIT FUNCTION
MODE DOOR MOTOR POSITION SENSE
5 VOLT SUPPLY
SENSOR RETURN
MODE DOOR MOTOR DRIVER
MODE DOOR MOTOR DRIVER
CAV
1
2
3
4
5
C39 20YL
C40 20DG/YL
D41 20LG/WT
C38 20DG
C37 20TN/BK
MODE DOOR
ACTUATOR
BLACK
1 2 3 4 5
CIRCUIT
-
-
-
-
-
FUNCTION
-
-
-
-
-
WIPER SWITCH MODE SENSE
WINDSHIELD WIPER SWITCH SIGNAL
WASHER SWITCH OUTPUT
WASHER SWITCH OUTPUT
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
WIPER SWITCH HIGH SPEED OUTPUT
WIPER SWITCH LOW SPEED OUTPUT
WIPER SWITCH LOW SPEED OUTPUT
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
WIPER SWITCH LOW SPEED OUTPUT
RIGHT TURN SIGNAL INDICATOR LAMP
LEFT TURN SIGNAL INDICATOR LAMP
HAZARD SIGNAL
TURN SIGNAL SWITCH OUTPUT
TURN SIGNAL SWITCH OUTPUT
TURN SIGNAL SWITCH OUTPUT
TURN SIGNAL
TURN SIGNAL
DIMMER SWITCH LOW BEAM OUTPUT
DIMMER SWITCH LOW BEAM OUTPUT
LOW HEADLAMP SWITCH SENSE
LOW HEADLAMP SWITCH SENSE
DIMMER SWITCH HIGH BEAM OUTPUT
FLASH TO PASS
CAV
1
2
4
5
7
8
9
10
11
12
13
14
15
20
21
22
23
24
V50 18LG/WT
V51 18WT
V11 18TN/BK
V11 18TN/BK
F86 16LG/BK
V4 18RD/YL
V3 18BR/WT
V3 18BR/WT
V6 16DB
V6 16DB
V3 18BR/WT
L64 18TN/DB
L60 18TN
L12 18VT/TN
L61 18DG
L65 18LG/DB
L65 18LG/DB
L5 18OR/BK
L5 18OR/BK
L4 16VT/OR
L4 16VT/OR
F34 16TN/BK
F34 16TN/BK
L3 16RD/OR
L11 16LG/BK
MULTI-FUNCTION
SWITCH
9 1
24
17 10
18
BLACK
3
6
16
17
18
19
8W - 80 - 58 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08058
CIRCUIT FUNCTION
SENSOR GROUND
OIL PRESSURE SENSOR SIGNAL
OIL PRESSURE SENSOR SIGNAL
SENSOR RETURN
CAV
1
1
2
2
K4 20BK/LB
G60 20GY/YL*
G6 18GY/WT
K167 20BR/YL*
BLACK
OIL PRESSURE
SENSOR
2 1
CIRCUIT FUNCTION
OUTPUT SHAFT SPEED SENSOR SIGNAL (+)
OUTPUT SHAFT SPEED SENSOR SIGNAL (-)
CAV
1
2
T14 18LG/WT
T13 18DB/BK
OUTPUT SHAFT
SPEED SENSOR
BLACK
1 2
CIRCUIT FUNCTION
FUSED IGNITION SWITCH OUTPUT (RUN)
GROUND
CCD BUS(+)
COURTESY LAMP RELAY OUTPUT
CCD BUS(-)
FUSED B(+)
CAV
1
2
3
4
5
6
F83 20YL/DG
Z1 20BK
D1 18VT/BR
M2 20YL
D2 18WT/BK
M1 20PK
OVERHEAD
CONSOLE
RED
3
4
1
6
* DIESEL
CIRCUIT FUNCTION
NEEDLE MOVEMENT SENSOR (+)
NEEDLE MOVEMENT SENSOR (-)
CAV
1
2
K67 20BR/BK
K68 20LG/YL
NEEDLE SENSOR
(DIESEL)
1
2
8W - 80 - 59 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08059
CIRCUIT FUNCTION
BACK-UP LAMP SWITCH OUTPUT
PARK/NEUTRAL POSITION SWITCH SENSE
FUSED IGNITION SWITCH OUTPUT (RUN)
CAV
1
2
3
L10 18BR/LG
T41 20BK/WT
F83 18YL/DG
BLACK
PARK/NEUTRAL POSITION
SWITCH
1 3
CIRCUIT FUNCTION
PASSENGER AIRBAG LINE 2
PASSENGER AIRBAG LINE 1
CAV
A
B
R44 18DB
R42 18VT
B A
PASSENGER
AIRBAG
YELLOW
CIRCUIT FUNCTION
RIGHT FRONT WINDOW DRIVER (UP)
RIGHT FRONT WINDOW DRIVER (DOWN)
RIGHT REAR WINDOW DRIVER (UP)
RIGHT REAR WINDOW DRIVER (DOWN)
RIGHT FRONT DOOR UNLOCK DRIVER
RIGHT FRONT DOOR LOCK DRIVER
GROUND
CCD BUS(+)
CCD BUS(-)
RIGHT REAR DOOR SWITCH ILLUMINATION
MUX COURTESY LAMP DRIVER
FUSED B(+)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
Q12 16BR
Q22 16VT
Q18 16GY/BK
Q28 16DG/WT
P34 18PK/BK
P2 18BK/WT
Z1 12BK
D1 18VT/BR
D2 18WT/BK
E20 18OR/DB
M1 20PK
F81 12TN
PASSENGER
DOOR
MODULE - C1
WHITE
6
12 7
1
CIRCUIT FUNCTION
HORIZONTAL DRIVER
HEATER SWITCHED GROUND
VERTICAL POSITION SENSOR SIGNAL
SENSOR GROUND
HORIZONTAL POSITION SENSOR SIGNAL
HEATER 12 VOLT SUPPLY
COMMON DRIVER
VERTICAL DRIVER
CAV
A
B
C
D
E
F
G
H
F75 20WT
Z1 20BK
F84 20GN
F86 20GY
F85 20VT
C16 20BK
F73 20DB
F71 20YL
BLACK
A
H
D
E
PASSENGER DOOR
MODULE - C2
8W - 80 - 60 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08060
CIRCUIT FUNCTION
GROUND
HEATED SEAT DRIVER
CAV
A
B
Z1 16BK
P88 16BR/BK
GREEN
PASSENGER HEATED
SEAT BACK
A B
CIRCUIT FUNCTION
HEATED SEAT DRIVER
HEATED SEAT DRIVER
PASSENGER HEATED SEAT SWITCH OUTPUT
GROUND
CAV
A
B
C
D
P87 16BK/OR
P88 16BR/BK
P8 18LB/WT
Z1 20BK
BLACK
PASSENGER HEATED
SEAT CUSHION
A
D
B
C
CIRCUIT FUNCTION
LUMBAR FORWARD DRIVER
LUMBAR REARWARD DRIVER
CAV
1
2
P106 18DG/WT
P107 18OR/BK
BLACK
PASSENGER
LUMBAR MOTOR
1 2
CIRCUIT FUNCTION
LUMBAR REARWARD DRIVER
GROUND
FUSE B(+)
GROUND
LUMBAR FORWARD DRIVER
CAV
1
2
3
4
5
P107 18OR/BK
Z1 18BK
F35 18RD
Z1 18BK
P106 18DG/WT
WHITE
PASSENGER LUMBAR
SWITCH
4
5
1
3
2
8W - 80 - 61 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08061
CIRCUIT FUNCTION
FRONT RISER DOWN SWITCH SENSE
FRONT RISER UP SWITCH SENSE
CAV
1
2
P20 16RD/LG
P18 16YL/LG
RED
PASSENGER POWER SEAT
FRONT RISER MOTOR
1 2
CIRCUIT FUNCTION
HORIZONTAL FORWARD SWITCH SENSE
HORIZONTAL REARWARD SWITCH SENSE
CAV
1
2
P14 16YL/LB
P16 16RD/LB
BLACK
PASSENGER POWER SEAT
HORIZONTAL MOTOR
1 2
CIRCUIT FUNCTION
REAR RISER DOWN SWITCH SENSE
REAR RISER UP SWITCH SENSE
CAV
1
2
P12 16RD/WT
P10 16YL/WT
RED
PASSENGER POWER SEAT
REAR RISER MOTOR
1 2
CIRCUIT FUNCTION
RECLINER DOWN DRIVER
RECLINER UP DRIVER
CAV
A
B
P42 16GY/WT
P44 16GY/LB
BLACK
PASSENGER POWER
SEAT RECLINER MOTOR
A B
CIRCUIT FUNCTION
GROUND
RECLINER UP DRIVER
HORIZONTAL REARWARD SWITCH SENSE
RECLINER DOWN DRIVER
FUSED B(+)
HORIZONTAL FORWARD SWITCH SENSE
FRONT RISER DOWN SWITCH SENSE
REAR RISER DOWN SWITCH SENSE
REAR RISER UP SWITCH SENSE
FRONT RISER UP SWITCH SENSE
CAV
1
2
3
4
5
6
7
8
9
10
Z1 18BK
P44 16GY/LB
P16 16RD/LB
P42 16GY/WT
F35 16RD
P14 16YL/LB
P20 16RD/LG
P12 16RD/WT
P10 16YL/WT
P18 16YL/LG
BLACK
PASSENGER POWER
SEAT SWITCH
6
1
10
5
8W - 80 - 62 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08062
PASSENGER SEAT HEATER
CONTROL MODULE
CIRCUIT
-
-
-
FUNCTION
-
-
-
FUSED IGNITION SWITCH OUTPUT
FUSED B(+)
HEATED SEAT DRIVER
GROUND
PASSENGER HEATED SEAT SWITCH OUTPUT
CAV
1
2
3
4
5
6
7
8
F87 18WT/BK
F35 16RD
P87 16BK/OR
Z1 18BK
P8 18LB/WT
1
4
3
8
GRAY
CIRCUIT
-
FUNCTION
-
AMPLIFIED RIGHT FRONT (+)
AMPLIFIED RIGHT FRONT (-)
AMPLIFIED RIGHT REAR (+)
RIGHT FRONT (+)
RIGHT REAR (-)
RIGHT REAR (+)
RADIO 12 VOLT OUTPUT
AMPLIFIED RIGHT REAR (-)
RIGHT FRONT (-)
CAV
1
2
3
4
5
6
7
8
9
10
X82 16LB/RD
X80 16LB/DG
X94 16TN/RD
X54 16VT
X58 16DB/OR
X52 16DB/WT
X60 18DG/RD
X92 16TN/BK
X56 16DB
CIRCUIT
-
-
FUNCTION
-
-
AMPLIFIED LEFT REAR (+)
FUSED B(+)
AMPLIFIED LEFT FRONT (+)
LEFT REAR (+)
LEFT FRONT (+)
AMPLIFIED LEFT REAR (-)
FUSED B(+)
AMPLIFIED LEFT FRONT (-)
GROUND
GROUND
LEFT REAR (-)
LEFT FRONT (-)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
X93 16WT/RD
F75 16VT
X87 16LG/RD
X51 16BR/YL
X53 16DG
X91 16WT/BK
F75 16VT
X85 16LG/BK
Z5 16BK/LB
Z5 16BK/LB
X57 16BR/LB
X55 16BR/RD
4
POWER AMPLIFIER - C1
WHITE
1
POWER AMPLIFIER - C2
WHITE
10
1
5
7
6
14
CIRCUIT FUNCTION
PEDAL POSITION SENSOR
LOW IDLE POSITION SWITCH
5 VOLT SUPPLY
SENSOR GROUND
THROTTLE POSITION SENSOR SIGNAL
CAV
3
5
7
8
10
K255 20WT/DG
K151 20WT
K6 20VT/WT
K4A 18BK/LB
K22 20OR/DB
PEDAL POSITION SENSOR
(DIESEL)
1 6
5 10
8W - 80 - 63 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08063
CIRCUIT
-
-
-
-
-
FUNCTION
-
-
-
-
FUSED B(+) POWER AMPLIFIER
RADIO GROUND
RIGHT FRONT SPEAKER(-)
LEFT FRONT SPEAKER (-)
RIGHT REAR SPEAKER(-)
LEFT REAR SPEAKER(-)
LEFT REAR SPEAKER (+)
RIGHT REAR SPEAKER (+)
LEFT FRONT SPEAKER (+)
RIGHT FRONT SPEAKER(+)
RADIO 12 VOLT OUTPUT
RADIO GROUND
FUSED B(+) POWER AMPLIFIER
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
F75 16VT
Z5 16BK/LB
X56 16DB
X55 16BR/RD
X58 16DB/OR
X57 16BR/LB
X51 16BR/YL
X52 16DB/WT
X53 16DG
X54 16VT
X60 18DG/RD
Z5 16BK/LB
F75 16VT
POWER AMPLIFIER
(LTD +) C1
CIRCUIT FUNCTION
AMPLIFIED RIGHT DOOR SPEAKER(+)
AMPLIFIED RIGHT SPEAKER DOOR (-)
AMPLIFIED LO LEFT REAR SPEAKER(-)
AMPLIFIED HI LEFT REAR SPEAKER(+)
AMPLIFIED RIGHT REAR SPEAKER(-)
AMPLIFIED RIGHT REAR SPEAKER(+)
AMPLIFIED HI RELT REAR SPEAKER(-)
RIGHT REAR SPEAKER(-)
RIGHT REAR SPEAKER(+)
AMPLIFIED LO LEFT REAR SPEAKER(+)
AMPLIFIED LEFT DOOR SPEAKER(-)
AMPLIFIED LEFT DOOR SPEAKER(+)
CAV
1
2
3
4
5
6
7
8
9
10
11
12
X82 16LB/RD
X80 16LB/DG
X91 16WT/BK
X95 16BR/YL
X96 16DB/OR
X98 16DB/WT
X97 16BR/LB
X94 16TN/RD
X92 16TN/BK
X93 16WT/RD
X85 16LG/BK
X87 16LG/RD
POWER AMPLIFIER
(LTD +) C2
BLACK
8
18
1
9
5
12
1
6
BLACK
8W - 80 - 64 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08064
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
1
2
F38 18OR
Z1 18BK
POWER OUTLET
BLACK
2
1
FUSED IGNITION SWITCH OUTPUT (START/RUN)
SENSOR GROUND
PARK NEUTRAL POSITION SWITCH SENSE
IGNITION COIL NO. 1 DRIVER
CRANKSHAFT POSITION SENSOR SIGNAL
IDLE AIR CONTROL NO. 4 DRIVER
IDLE AIR CONTROL NO. 3 DRIVER
INTAKE AIR TEMPERATURE SENSOR SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
5 VOLT SUPPLY
CAMSHAFT POSITION SENSOR SIGNAL
IDLE AIR CONTROL NO. 2 DRIVER
IDLE AIR CONTROL NO. 1 DRIVER
FUSED B(+)
THROTTLE POSITION SENSOR SIGNAL
UPSTREAM HEATED OXYGEN SENSOR SIGNAL
DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL
MAP SENSOR SIGNAL
GROUND
GROUND
F99 18OR
K4 18BK/LB
T41 18BK/WT
K19 18GY/WT
K27 18RD/LG
K59 16VT/BK
K40 16BR/WT
K21 16BK/RD
K2 16TN/BK
K25 18WT/BK
K24 18GY/BK
K60 16YL/BK
K39 16GY/RD
F5 14RD/YL
K22 18OR/DB
K41 18BK/OR
K141 18BK/PK
K70 18RD/WT
Z12 14BK/TN
Z12 14BK/TN
CAV
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27
A28
A29
A30
A31
A32
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
-
-
-
-
POWERTRAIN CONTROL
MODULE - C1
1 11
22
12 21
32
BLACK
8W - 80 - 65 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08065
TRANSMISSION TEMPERATURE SENSOR SIGNAL
INJECTOR NO. 7 DRIVER
INJECTOR NO. 1 DRIVER
INJECTOR NO. 3 DRIVER
INJECTOR NO. 5 DRIVER
VARIABLE FORCE SOLENOID CONTROL
GENERATOR FIELD DRIVER
TORQUE CONVERTER CLUTCH SOLENOID CONTROL
INJECTOR NO. 6 DRIVER
INJECTOR NO. 8 DRIVER
INJECTOR NO. 2 DRIVER
INJECTOR NO. 4 DRIVER
OVERDRIVE SOLENOID CONTROL
OIL PRESSURE SENSOR SIGNAL
OUTPUT SHAFT SPEED SENSOR SIGNAL (-)
VEHICLE SPEED SENSOR SIGNAL
OUTPUT SHAFT SPEED SENSOR SIGNAL (+)
GOVERNOR PRESSURE SIGNAL
TRANSMISSION RELAY CONTROL
5 VOLT SUPPLY
T54 18VT
K17 18DB/WT*
K11 18WT/DB
K13 18YL/WT
K38 18GY
T59 18PK
K20 18DG
T22 18DG/LB
K58 18BR/YL
K18 18DB/YL*
K12 18TN
K14 18LB/BR
T60 18BR
G6 18GY/WT
T13 18DB/BK
G7 18WT/OR
T14 18LG/WT
T25 18LG
T66 20BR/OR
K6 18VT/WT
CAV
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
B21
B22
B23
B24
B25
B26
B27
B28
B29
B30
B31
B32
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
-
-
-
-
POWERTRAIN CONTROL
MODULE - C2
1 11
22
12 21
32
WHITE
* WITH 5.2L ENG
8W - 80 - 66 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08066
A/C COMPRESSOR CLUTCH RELAY CONTROL
AUTOMATIC SHUT DOWN RELAY CONTROL
SPEED CONTROL VACUUM SOLENOID CONTROL
SPEED CONTROL VENT SOLENOID CONTROL
OVERDRIVE OFF LAMP DRIVER
VAPOR CANISTER SOLENOID DRIVER
SPEED CONTROL ON/OFF SWITCH SENSE
AUTOMATIC SHUT DOWN RELAY OUTPUT
OVERDRIVE OFF SWITCH SENSE
VAPOR CANISTER PUMP SWITCH DRIVER
BATTERY TEMPERATURE SENSE SIGNAL
FUEL PUMP RELAY CONTROL
EVAPORATIVE EMISSION SOLENOID CONTROL
A/C PRESSURE SWITCH SENSE
STOP LAMP SWITCH SENSE
VOLTAGE REGULATOR SIGNAL
LOW FUEL SENSE
SCI RECEIVE
CCD BUS (-)
SCI TRANSMIT
CCD BUS (+)
SPEED CONTROL SWITCH SIGNAL
C13 18DB/RD
K900 18PK/WT
V36 18TN/RD
V35 18LG/RD
G68 18BR/YL
J95 18DG/RD
V32 18YL/RD
A142 18DG/OR
T9 18OR
J96 18VT/RD
T222 18RD/YL
K81 18DB
K52 18PK/BK
C3 18DB/BK
L53 18BR
K72 18DG/VT
G40 18LB/BK
D83 18BK/PK
D2 18WT/BK
D84 18BK/WT
D1 18VT/BR
K95 18PK
CAV
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
C26
C27
C28
C29
C30
C31
C32
C142
CIRCUIT
-
-
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
-
-
POWERTRAIN CONTROL
MODULE - C3
32 22
11
21 12
1
GRAY
8W - 80 - 67 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08067
LOW FUEL WARNING
FUSED B(+)
SENSOR GROUND
5 VOLT SUPPLY
COOLANT LEVEL SENSOR
FUSED IGNITION SWITCH OUTPUT
GROUND
GROUND
GENERATOR FIELD DRIVER
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
THROTTLE POSITION SENSOR SIGNAL
WATER-IN-FUEL SENSE
DISTRIBUTOR PICK-UP SIGNAL
SCI RECEIVE
CCD BUS(+)
STOP LAMP SWITCH SENSE
SPEED CONTROL SWITCH SIGNAL
OIL PRESSURE SENSOR SIGNAL
WAIT TO START LAMP
SCI TRANSMIT
CCD BUS(-)
VEHICLE SPEED SENSOR SIGNAL
ENGINE COOLANT LEVEL SIGNAL
AUTOMATIC SHUT DOWN RELAY OUTPUT
A/C SWITCH SIGNAL
G40 18LB/BK
F6 18WT/RD
K167 20BR/YL
K7 20OR/WT
G18 20PK/BK
F99 18OR
Z12 16BK/TN
Z12 16BK/TN
K20 18DG/YL
K222 20TN/RD
K48 18OR/RD
G123 20DG/WT
G21 20GY/LB
D83 20BK/PK
D1 18VT/BR
L53 20BR
K92 20PK
G60 20GY/YL
K185 18OR/LB
D84 20BK/WT
D2 18WT/BK
G7 20WT/OR
G118 20PK/DB
A142 16DG/OR
C103 20DG
CAV
1
3
4
6
8
9
11
12
20
21
22
23
24
25
26
29
41
42
44
45
46
47
54
57
59
CIRCUIT FUNCTION
POWERTRAIN CONTROL MODULE - C4
(DIESEL)
(CAVITIES NOT SHOWN ARE NOT USED)
BLACK
41 21 1
60 40 20
8W - 80 - 68 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08068
CIRCUIT
-
FUNCTION
-
LEFT FRONT (-)
RIGHT FRONT (-)
PARK LAMP RELAY OUTPUT
PANEL LAMP DRIVER
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
FUSED B(+)
CAV
1
2
3
4
5
6
7
X55 20BR/RD
X56 20DB
L90 20DB/RD
E2 20OR
X12 18RD/GY
F60 20RD/WT
RADIO - C1
GRAY
1 7
CIRCUIT FUNCTION
CCD BUS (+)
CCD BUS (-)
CAV
1
2
D1 18VT/BR
D2 18WT/BK
BLACK
RADIO - C2
2 1
CIRCUIT FUNCTION
RADIO 12 VOLT OUTPUT
LEFT REAR (+)
RIGHT REAR (+)
LEFT FRONT (+)
RIGHT FRONT (+)
LEFT REAR (-)
RIGHT REAR (-)
CAV
1
2
3
4
5
6
7
X60 20DG/RD
X51 20BR/YL
X52 20DB/WT
X53 20DG
X54 20VT/YL
X57 20BR/LB
X58 20DB/OR
BLACK
1
RADIO - C3
7
CIRCUIT FUNCTION CAV
A
B
C
D
X96 16DB/OR
X98 16DB/WT
X97 16BR/LB
X95 16BR/YL
REAR
SPEAKER
A B
D C
BLACK
8W - 80 - 69 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08069
REAR WASHER
PUMP MOTOR
BLACK
CIRCUIT FUNCTION
REAR WASHER MOTOR CONTROL
GROUND
CAV
1
2
V20 18WT/BK
Z2 18BK
1
2
CIRCUIT FUNCTION
FUSED (B+)
REAR WIPER MOTOR CONTROL
GROUND
REAR WIPER MOTOR CONTROL (INT)
REAR WASHER MOTOR CONTROL
LIFTGATE AJAR SWITCH SENSE
CAV
1
2
3
4
5
6
F70 16PK/BK
V13 18BR/LG
Z1 14BK
V24 18BR/OR
V20 18BK/WT
G78 20TN/BK
BLACK
3
REAR WIPER
MODULE
4
1
6
CIRCUIT FUNCTION
REAR WIPER MOTOR CONTROL
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
REAR WIPER MOTOR CONTROL (INT)
REAR WASHER MOTOR CONTROL
REAR WASHER MOTOR CONTROL
CAV
1
2
3
4
V13 18BR/LG
V23 18BR/PK
V24 18BR/OR
V20 18WT/BK
V20 18WT/BK
REAR WIPER/WASHER SWITCH
1
BLACK
4
CIRCUIT
-
-
FUNCTION
-
-
RECIRCULATION DOOR MOTOR DRIVER
RECIRCULATION DOOR MOTOR DRIVER
FUSED IGNITION SWITCH OUTPUT (RUN)
CAV
1
2
3
4
5
C33 20VT/OR
C32 20LB/DG
F71 20PK/DG
RECIRCULATION DOOR
ACTUATOR
(WITH AUTOMATIC
TEMPERATURE CONTROL)
YELLOW
1 2 3 4 5
8W - 80 - 70 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08070
CIRCUIT FUNCTION
RIGHT IMPACT SENSOR LINE 1
RIGHT IMPACT SENSOR LINE 2
CAV
1
2
R46 18BR/LB
R48 18TN
RIGHT AIRBAG
SENSOR
BLACK
2 1
CIRCUIT FUNCTION
BACK-UP LAMP SWITCH OUTPUT
GROUND
CAV
A
G
L10 18BR/LG
Z1 18BK
BLACK
RIGHT BACK-UP LAMP
A
G
CIRCUIT FUNCTION
FUSED B(+)
COURTESY LAMP RELAY OUTPUT
CAV
A
B
M1 20PK
M2 20YL
RIGHT
COURTESY LAMP
BLACK
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
1
2
M1 20PK
Z1 20BK
BLACK
2 1
RIGHT DOOR
COURTESY LAMP
CIRCUIT FUNCTION
GROUND
FOG LAMP RELAY OUTPUT
CAV
1
2
Z1 18BK
L39 18LB
RIGHT FOG LAMP
1 2
BLACK
8W - 80 - 71 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08071
CIRCUIT FUNCTION
VTSS DISARM SENSE
GROUND
CAV
1
2
G71 20VT/YL
Z1 20BK
BLACK
2 1
RIGHT FRONT CYLINDER
LOCK SWITCH
CIRCUIT FUNCTION
DOOR UNLOCK DRIVER
DOOR LOCK DRIVER
CAV
1
2
P34 14PK/BK
P2 14BK/WT
BLACK
2 1
RIGHT FRONT DOOR
LOCK MOTOR
CIRCUIT FUNCTION
RIGHT FRONT (+)
RIGHT FRONT (-)
CAV
A
B
X54 20VT
X56 20DB/RD
RIGHT FRONT
DOOR SPEAKER
BLACK
A B
CIRCUIT FUNCTION
PARK LAMP RELAY OUTPUT
GROUND
CAV
A
B
L90 18DB/RD
Z1 18BK
WHITE
RIGHT FRONT PARK LAMP
B A
CIRCUIT FUNCTION
RIGHT FRONT WINDOW DRIVER (UP)
RIGHT FRONT WINDOW DRIVER (DOWN)
CAV
1
2
Q12 16BR
Q22 16VT
BLACK
RIGHT FRONT POWER
WINDOW MOTOR
2 1
8W - 80 - 73 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08073
CIRCUIT FUNCTION
PARK LAMP RELAY OUTPUT
GROUND
CAV
1
2
L90 20DB/RD
Z1 20BK
NATURAL
RIGHT LICENSE LAMP
1 2
CIRCUIT FUNCTION
DOOR UNLOCK DRIVER
DOOR LOCK DRIVER
CAV
1
2
P34 18PK/BK
P2 18BK/WT
RIGHT REAR DOOR
LOCK MOTOR
BLACK
1 2
CIRCUIT FUNCTION
RIGHT REAR (+)
RIGHT REAR (-)
CAV
A
B
X52 20DB/WT
X58 20DB/OR
B
RIGHT REAR
DOOR SPEAKER
BLACK
A
CIRCUIT FUNCTION
PARK LAMP RELAY OUTPUT
GROUND
CAV
1
2
L90 18DB/RD
Z1 18BK
NATURAL
RIGHT PARK LAMP
1 2
CIRCUIT FUNCTION
REAR FOG LAMP
GROUND
CAV
A
G
L36 18LG/BK
Z1 18BK
RIGHT REAR
FOG LAMP
CIRCUIT FUNCTION
RIGHT TURN SIGNAL
PARK LAMP SWITCH OUTPUT
GROUND
CAV
1
2
3
L64 18TN/DB
L90 18DB/RD
Z1 18BK
RIGHT PARK TURN
SIGNAL MARKER
2 1
3
BLACK
8W - 80 - 74 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08074
CIRCUIT FUNCTION
GROUND
PARK LAMP SWITCH OUTPUT
CAV
1
2
Z1 18BK
L22 18LB
NATURAL
RIGHT REAR SIDE
MARKER LAMP
1 2
CIRCUIT FUNCTION
TURN SIGNAL SWITCH OUTPUT
GROUND
CAV
A
G
L61 18LG
Z1 18BK
BLACK
RIGHT REAR TURN
SIGNAL LAMP
A
G
FUNCTION CIRCUIT
RIGHT REAR WHEEL SPEED SENSOR (-)
RIGHT REAR WHEEL SPEED SENSOR (+)
CAV
A
B
B1 20YL/DB
B2 20YL
RIGHT REAR WHEEL
SPEED SENSOR
A B
RED
CIRCUIT FUNCTION
RIGHT REAR WINDOW DRIVER (UP)
RIGHT REAR WINDOW DRIVER (UP)
RIGHT REAR DOOR SWITCH ILLUMINATION
RIGHT REAR WINDOW DRIVER (DOWN)
RIGHT REAR WINDOW DRIVER (DOWN)
GROUND
CAV
1
2
3
4
5
6
Q18 16GY/BK
Q12 16BR
E20 20OR/DG
Q28 16DG/WT
Q22 16VT
Z1 16BK
1
4
3
6
RIGHT REAR POWER
WINDOW SWITCH
BLUE
CIRCUIT FUNCTION
RIGHT REAR WINDOW DRIVER (UP)
RIGHT REAR WINDOW DRIVER (DOWN)
CAV
1
2
Q12 16BR
Q22 16VT
2
RIGHT REAR POWER
WINDOW MOTOR
BLACK
1
8W - 80 - 75 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08075
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
A
B
M1 20PK
Z1 20BK
A
RIGHT VISOR/
VANITY MIRROR
BLACK
B
CIRCUIT FUNCTION
SEAT BELT SWITCH SENSE
GROUND
CAV
1
2
G10 20LG/RD
Z1 20BK
SEAT BELT
SWITCH
CIRCUIT FUNCTION
SHIFT INTERLOCK SOLENOID SENSE
FUSED IGNITION SWITCH OUTPUT
CAV
1
2
L53 20BR
F87 20BK/WT
SHIFT INTERLOCK
SOLAR SENSOR
CIRCUIT FUNCTION
SOLOR SENSOR SIGNAL
SENSOR GROUND
CAV
A
B
C47 20BK/WT
D41 20LG/WT
A
RED
B
1
BLACK
2
1
BLACK
2
CIRCUIT FUNCTION
STOP LAMP SWITCH OUTPUT
PARK LAMP SWITCH OUTPUT
GROUND
CAV
A
B
G
L74 18PK/BK
L21 18LB/WT
Z1 18BK
BLACK
RIGHT TAIL/STOP LAMP
B
A
G
FUNCTION CIRCUIT
GROUND
RIGHT TURN SIGNAL
CAV
1
2
Z1 18BK
L64 18LG/DB
RIGHT SIDE REPEATER
8W - 80 - 76 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08076
SPEED PROPORTIONAL
STEERING MODULE
GREEN
CIRCUIT
-
-
-
FUNCTION
-
-
-
SPEED PROPORTIONAL STEERING SOLENOID CONTROL
LOW
SPEED PROPORTIONAL STEERING SOLENOID CONTROL
HIGH
STEERING WHEEL SPEED SENSOR GROUND
5 VOLT SUPPLY
VEHICLE SPEED SENSOR SIGNAL
FUSED IGNITION SWITCH OUTPUT (RUN)
STEERING WHEEL SPEED SENSOR SIGNAL B
GROUND
SCI TRANSMIT
SCI RECEIVE
STEERING WHEEL SPEED SENSOR SIGNAL A
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
S99 18LG
S98 18LB
S2 20BK/LG
S1 20BK/YL
G7 18WT/OR
F83 20YL/DG
S4 20VT
Z2 20BK
D83 20BK/PK
D98 20WT
S3 20PK/WT
14 7
6 1
CIRCUIT FUNCTION
SPS SOLENOID CTL HIGH
SPS SOLENOID CTL LOW
CAV
1
2
S98 18LB
S99 18LG
SPEED PROPORTIONAL
STEERING SOLENOID
1 2
BLACK
8W - 80 - 77 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08077
STEERING WHEEL
SPEED SENSOR
CIRCUIT FUNCTION
5 VOLT SUPPLY
STEERING WHEEL SPEED SENSOR GROUND
STEERING WHEEL SPEED SENSOR SIGNAL A
STEERING WHEEL SPEED SENSOR SIGNAL B
CAV
A
B
C
D
S1 20BK/YL
S2 20BK/LG
S3 20PK/WT
S4 20VT
A D
NATURAL
CIRCUIT
-
FUNCTION
-
DRIVER HEATED SEAT SWITCH OUTPUT
GROUND
PANEL LAMP DRIVER
PASSENGER HEATED SEAT SWITCH OUTPUT
FUSED IGNITION SWITCH OUTPUT (RUN)
OVERDRIVE OFF SWITCH SENSE
OVERDRIVE OFF LAMP DRIVER
REAR WINDOW DEFOGGER SWITCH SENSE
FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
CAV
1
2
3
4
5
6
7
8
9
10
P7 20LB
Z1 20BK
E2 20OR
P8 20LB/WT
F71 20PK/DG
T9 20OR
G68 20BR/YL
C80 20DB/YL
C16 20LB/YL
SWITCH POD
1
BLACK
10
CIRCUIT FUNCTION
GROUND
POWER SUNROOF OPEN
POWER SUNROOF CLOSE
FUSED IGNITION SWITCH OUTPUT
CAV
1
2
3
4
Z1 16BK
Q41 18WT
Q42 18LB
F86 18LG/BK
SUNROOF CONTROL
MODULE
CIRCUIT FUNCTION
STOP LAMP SWITCH SENSE
GROUND
SPEED CONTROL ON/OFF SWITCH SENSE
SPEED CONTROL STOP LAMP SWITCH OUTPUT
STOP LAMP SWITCH OUTPUT
FUSED B(+)
CAV
1
2
3
4
5
6
L53 20BR
Z1 20BK
V32 20YL/RD
V30 20DB/LG
L50 18WT/TN
L16 18RD/LG
STOP LAMP SWITCH
GRAY
6 5 4 3 2 1
1 4
BLACK
8W - 80 - 78 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08078
CIRCUIT FUNCTION
5 VOLT SUPPLY
THROTTLE POSITION SENSOR SIGNAL
SENSOR GROUND
CAV
*1
*2
*3
K25 20WT/BK
K22 18OR/DB
K4 20BK/LB
BLACK
THROTTLE
POSITION SENSOR
3 2 1
CIRCUIT FUNCTION
FUSED B(+)
FUSED B(+)
CAV
A
B
F70 16PK/BK
F70 16PK/BK
BLACK
A B
TRAILER TOW
CIRCUIT BREAKER
CIRCUIT FUNCTION
LEFT TURN SIGNAL
GROUND
LEFT TURN SIGNAL
FACTORY TRAILER TOW RELAY OUTPUTS
FACTORY TRAILER TOW RELAY OUTPUTS
FACTORY TRAILER TOW RELAY OUTPUTS
FACTORY TRAILER TOW RELAY OUTPUTS
CAV
1
2
3
4
5
L61 18LG
Z1 18BK
L61 18LG/OR
95 18PK
95 18PK
94 18DG
94 18DG
TRAILER TOW
LEFT TURN RELAY
BLACK
3 5
2
4
1
CAV
3
2
1
* 5.2L V-8
4.0L I-6
CIRCUIT
-
-
-
FUNCTION
-
-
-
RIGHT TURN SIGNAL
GROUND
RIGHT TURN SIGNAL
FACTORY TRAILER TOW RELAY OUTPUTS
FACTORY TRAILER TOW RELAY OUTPUTS
CAV
1
2
3
4
5
6
7
8
L60 18TN
Z1 18BK
L60 18TN/OR
95 18PK
94 18DG
TRAILER TOW
RIGHT TURN RELAY
BLACK
3 5
2
4
1
8W - 80 - 79 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08079
CIRCUIT FUNCTION
STOP LAMP SWITCH OUTPUT
GROUND
FUSED B(+)
FACTORY TRAILER TOW RELAY OUTPUTS
FACTORY TRAILER TOW RELAY OUTPUTS
CAV
1
2
3
4
5
L50 18WT/TN
Z1 18BK
F70 16PK/BK
94 18DG
95 18PK
TRAILER TOW
STOP LAMP RELAY
BLACK
3 5
2
4
1
CIRCUIT FUNCTION
LOW/REVERSE SOLENOID CONTROL
5 VOLT SUPPLY
SENSOR GROUND
GOVERNOR PRESSURE SIGNAL
VARIABLE FORCE SOLENOID CONTROL
OVERDRIVE SOLENOID CONTROL
TORQUE CONVERTER CLUTCH SOLENOID OUTPUT
TRANSMISSION TEMPERATURE SENSOR SIGNAL
CAV
1
2
3
4
5
6
7
8
T20 18LB
K6 18VT/WT
K4 18BK/LB
T25 18LG
T59 18PK
T60 18BR
T22 18DG/LB
T54 18VT
1
2
3
4
5
6
7
8
BLACK
TRANSMISSION
SOLENOID ASSEMBLY
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
1
2
M1 18PK
Z1 18BK
UNDERHOOD LAMP
BLACK
1 2
GRAY
CIRCUIT FUNCTION
AUTOMATIC SHUTDOWN RELAY OUTPUT
GROUND
SENSOR GROUND
UPSTREAM HEATED OXYGEN SENSOR SIGNAL
CAV
1
2
3
4
A142 18DG/OR
Z12 18BK/TN
K4 18BK/LB
K41 18BK/OR
UPSTREAM
HEATED OXYGEN
SENSOR
2
4
1
3
8W - 80 - 80 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08080
CIRCUIT FUNCTION
SPEED CONTROL VACUUM SOLENOID CONTROL
SPEED CONTROL VENT SOLENOID CONTROL
SPEED CONTROL STOP LAMP SWITCH OUTPUT
GROUND
CAV
1
2
3
4
V36 18TN/RD
V35 18LG/RD
V30 20DB/LG
Z4 20BK
VEHICLE SPEED
CONTROL SERVO
BLACK
1 4
CIRCUIT FUNCTION
SPEED CONTROL SWITCH SIGNAL
SENSOR GROUND
RADIO CONTROL MUX
GROUND
HORN SWITCH
CAV
1
2
3
4
5
K95 20PK
K4 18BK/LB
709 20RD/BK
Z2 20BK/OR
X4 20GY/OR
NATURAL
VEHICLE SPEED CONTROL/
HORN SWITCH
1 5
CIRCUIT
-
-
-
FUNCTION
-
-
-
ENGINE COOLANT LEVEL SWITCH SENSE
FUSED B(+)
GROUND
TURN SIGNAL
REAR LAMP OUT INDICATOR DRIVER
CCD BUS (+)
CCD BUS (-)
PANEL LAMP DRIVER
PARK LAMP RELAY OUTPUT
WASHER FLUID LEVEL SENSE
4-WHEEL DRIVE PART TIME LAMP
4-WHEEL DRIVE FULL TIME LAMP
FUSED IGNITION SWITCH OUTPUT (RUN)
4-WHEEL DRIVE PART TIME LAMP
ALL TIME FRONT WHEELS
2-WHEEL DRIVE OR REAR WHEELS IN ALL TIME
GROUND
CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
G18 20PK/BK
F60 20RD/WT
Z2 20BK/OR
L5 18OR/BK
G46 20BK/LB
D1 18VT/BR
D2 18WT/BK
E2 20OR
L90 20DB/RD
G29 2OBK/TN
107 20BK/RD
T106 20GY/OR
F83 18YL/DG
T19 20YL/BK
G42 20LB/RD
G28 20LG/OR
Z1 20BK
VEHICLE
INFORMATION CENTER
BLACK
10 1
20 11
CIRCUIT FUNCTION
5 VOLT SUPPLY
SENSOR GROUND
VEHICLE SPEED SENSOR SIGNAL
CAV
1
2
3
K6 18VT/WT
K4 18BK/LB
G7 18WT/OR
1 3
VEHICLE SPEED SENSOR
(GAS)
BLACK
8W - 80 - 81 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08081
CIRCUIT FUNCTION
WASHER SWITCH OUTPUT
GROUND
CAV
A
B
V11 18TN/BK
Z2 18BK
CIRCUIT
-
FUNCTION
-
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
WIPER PARK SWITCH SENSE
GROUND
WIPER SWITCH LOW SPEED OUTPUT
WIPER SWITCH HIGH SPEED OUTPUT
CAV
1
2
3
4
5
6
F86 16LG/RD
V66 18VT/WT
Z2 18BK
V3 18BR/WT
V4 18RD/YL
WINDSHIELD WASHER
PUMP MOTOR
WINDSHIELD
WIPER MOTOR
BLACK
A B
BLACK
1
4
3
6
CIRCUIT FUNCTION
WASHER FLUID LEVEL SENSE
GROUND
CAV
A
B
G29 16BK/TN
Z2 16BK
WIPER
FLUID LEVEL
SENSOR
BLACK
B A
CIRCUIT FUNCTION
8 VOLT SUPPLY
SENSOR GROUND
VEHICLE SPEED SENSOR SIGNAL
CAV
1
2
3
K7 20OR
K167 20BR/YL
G7 20WT/OR
VEHICLE SPEED SENSOR
(DIESEL)
CIRCUIT FUNCTION
WATER IN FUEL SENSE
SENSOR RETURN
CAV
1
2
G123 20DG/WT
K167 20BR/YL
WATER IN FUEL SENSOR
(DIESEL)
2
1
1
2
3
8W-90 CONNECTOR LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng com-
ponent and connector l ocati ons i n the vehi cl e. A con-
nector i ndex i s provi ded. Use the wi ri ng di agrams i n
each secti on for connector number i denti fi cati on.
Refer to the i ndex for the proper fi gure number.
CONNECTOR/GROUND LOCATIONS
For i tems that are not shown i n thi s secti on N/S i s
pl aced i n the Fi g. col umn.
Connector
Name/Number
Color Location Fig.
A/C Heater
Control
BK Rear of Switch 15
A/C High
Pressure Switch
BK Near A/C
Compressor
5
A/C Low Pressure
Switch
BK Right Rear Corner
of Engine
Compartment
2
After Market
Trailer Tow
Connector
BK Left Rear Quarter
Panel
N/S
Airbag Control
Module C1
BK Below Center Floor
Console, Near Park
Brake
18
Airbag Control
Module C2
YL Below Center Floor
Console, Near Park
Brake
18
Ambient
Temperature
Sensor
BK On Radiator Center
Support
1
Auto Headlamp
Light Sensor
VTSS LED
BK Top of Instrument
Panel, Between
Steering Column
and Center Floor
Console
14
Automatic
Day/Night
Rearview Mirror
BK Behind Rear View
Mirror
17
Automatic
Temperature
Control Module
BK Left Side of HVAC
Housing
14
Battery
Temperature
Sensor
BK Below Battery Tray 3
Blend Air Door
Motor
BK On Bottom of HVAC
Unit
N/S
Blend Air Actuator BK On Bottom of HVAC
Unit
N/S
Blower Motor NAT Right Side of HVAC N/S
Connector
Name/Number
Color Location Fig.
Blower Motor
Resistor Block
BK Right Side of HVAC N/S
Blower Motor
Switch
BK On HVAC Unit N/S
Blower Power
Module
BK On HVAC Unit N/S
Body Control
Module C1
BK Lower Left of
Instrument Panel
N/S
Body Control
Module C2
WT Lower Left of
Instrument Panel
N/S
Body Control
Module C3
BK Lower Left of
Instrument Panel
N/S
Brake Warning
Switch
BK Near Brake Master
Cylinder
3
C102 BK Rear of Fog Lamp 1
C131 BK Right Rear Corner
of Engine
Compartment, Near
PCM
2
C132 BK Right Rear Corner
of Engine
Compartment, Near
PCM
2
C137 BK Rear of Engine
(Diesel Engine)
13
C142 BK Corner of Engine
Compartment At
PCM
N/S
C144 BK Below PDC 12
C150 BK Rear of Fog Lamp 1
C160 BK Corner of Instrument
Panel
N/S
C206 BK On Front of HVAC
Unit
N/S
C212 RD Center of Instrument
Panel
N/S
ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 1
Connector
Name/Number
Color Location Fig.
C213 GN Behind Right Kick
Panel, At Junction
Block
N/S
C231 BK Right End of
Instrument Panel
N/S
C233 BK Lower Left
Instrument Panel, In
Connector Bracket
N/S
C234 WT Lower Instrument
Panel, In Connector
Bracket
N/S
C235 BK Lower Instrument
Panel, In Connector
Bracket
N/S
C236 WT Lower Instrument
Panel, In Connector
Bracket
N/S
C300 YL Lower Instrument
Panel
N/S
C301 NAT Lower Instrument
Panel, In Connector
Bracket
N/S
C302 WT Lower Instrument
Panel, In Connector
Bracket
N/S
C304 GY Lower Instrument
Panel
N/S
C305 BK Lower Instrument
Panel, In Connector
Bracket
N/S
C307 BK Lower Instrument
Panel
N/S
C309 GY In Left Rear Door 21
C320 GY Right Rear Quarter
Panel, Near Bottom
of Liftgate Opening
18
C321 BK In Liftgate 23
C322 GN In Liftgate 23
C323 GY In Liftgate 23
C324 BK In Liftgate 23
C325 BK In Liftgate 23
C326 GY In Liftgate 23
C328 GY Left Rear Quarter
Panel, Near Bottom
of Liftgate Opening
19
C329 BK Below Left Rear
Passenger Seat
19
Connector
Name/Number
Color Location Fig.
C330 GY In Right Rear Door 21
C334 BK In Left Front Door 20
C335 BK Below Left Rear
Passenger Seat
18
C343 BK In Left Rear Door 21
C345 BK In Right Rear Door 21
C351 GY In Right Front Door 20
C353 BK In Left Front Door 20
C359 BK In Liftgate 23
C364 BK In Liftgate 23
C372 BK Right Rear Quarter
Panel
22
C906 BK Rear of Engine
(Diesel)
11
C907 BK At Fuel Filter 11
C908 BK At Fuel Filter 11
C914 BK Below PDC 12
C917 BK Near Generator N/S
Camshaft Position
Sensor
BK Near Distributor 5, 9
Cargo Lamp BK Rear of Cargo Lamp 18
Center High
Mounted Stop
Lamp Bulb No. 1
BK At Lamp N/S
Center High
Mounted Stop
Lamp Bulb No. 2
BK At Lamp N/S
Center High
Mounted Stop
Lamp Bulb No. 3
BK At Lamp N/S
Cigar Lighter BK Rear of Cigar
Lighter
14
Controller
Anti-Lock Brake
BK At Anti-Lock Brake
Controller
N/S
Crankshaft
Position Sensor
BK Right Rear of
Engine 4.0L Engine
Rear of Engine 5.2L
Engine
5, 9
Data Link
Connector
BK Lower Instrument
Panel
N/S
Daytime Running
Lamp Module
BK Right Fender Side
Shield, Below PDC
N/S
Dome/Reading
Lamp
NAT Behind Dome Lamp 17
8W - 90 - 2 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
Downstream
Heated Oxygen
Sensor
BK Above Rear of
Catalytic Converter
7, 10
Driver Door
Module C1
WT In Left Front Door 20
Driver Door
Module C2
BK In Drivers Door N/S
Driver Door
Module C3
BK In Drivers Door N/S
Driver Heated
Seat Back
BK Under Drivers Seat N/S
Driver Heated
Seat Cushion
BK Under Drivers Seat N/S
Driver Lumbar
Motor
BK Under Drivers Seat N/S
Driver Power Seat
Front Riser Motor
RD Under Drivers Seat N/S
Driver Power Seat
Front Riser Motor
Sensor
BK Under Drivers Seat N/S
Driver Power Seat
Horizontal Motor
BK Under Drivers Seat N/S
Driver Power Seat
Horizontal Motor
Sensor
BK Under Drivers Seat N/S
Driver Power Seat
Lumbar Motor
Sensor
BK Under Drivers Seat N/S
Driver Power Seat
Lumbar Switch
BK Under Drivers Seat N/S
Driver Power Seat
Rear Riser Motor
RD Under Drivers Seat N/S
Driver Power Seat
Rear Riser Motor
Sensor
BK Under Drivers Seat N/S
Driver Power Seat
Recliner Motor
BK Under Drivers Seat N/S
Driver Power Seat
Recliner Motor
Sensor
BK Under Drivers Seat N/S
Driver Power Seat
Switch
GN Under Drivers Seat N/S
Driver Seat
Heater Control
Module
BK Under Drivers Seat N/S
Driver Side Airbag YL Lower Instrument
Panel
16
Connector
Name/Number
Color Location Fig.
Duty Cycle
EVAP/Purge
Solenoid
BK Front of Left Fender
Side Shield
4
Engine Coolant
Level Sensor
BK Top of Reserve Tank 3
Engine Coolant
Temperature
Sensor
BK On Thermostat
Housing Rear of
Generator
5, 8
Engine Starter
Motor
BK At Starter Motor 6, 8
Evaporative
System Leak
Detection Pump
BK Front of Left Fender
Side Shield
N/S
Factory Trailer
Tow Connector
BK On Trailer Hitch 22
Floor Console
Lamps
BK Left Side of Center
Floor Console
18
Four-Wheel Drive
Switch
BK Left Front of
Transfer Case
7, 10
Fuel Heater BK At Fuel Heater/Filter 11
Fuel Pump
Module
BK Near Fuel Tank 18
G100 Right Fender Side
Shield
2
G101 Right Side of Engine
Block 4.0L Engine
Below Generator
5.2L Engine
6, 8
G103 Right Side of Engine
Block 4.0L Engine
Below Generator
5.2L Engine
8
G104 Right Side of Engine
Block 4.0L Engine
8
G104 Below Generator
5.2L Engine
8
G104 Below A/C
Compressor Diesel
Engine
13
G105 Right Rear of
Engine 4.0L Engine
Below A/C
Compressor 5.2L
Engine
5, 9
G106 Right Fender Side
Shield
2
G107 Right Fender Side
Shield
2
ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 3
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
G108 Front of Left Fender
Side Shield
4
G109 Front of Left Fender
Side Shield
4
G300 Right Rear Quarter
Panel
18
G301 Rear of Drivers
Seat
18
G302 On Floor Pan Rear
of Seat
19
G303 On Floor Pan Rear
of Seat
19
G304 On Floor Pan Rear
of Seat
19
G305 On Floor Pan Rear
of Seat
19
G-Switch BK Below Right Rear
Seat
18
Generator BK At Generator 6
Glove Box Lamp BK At Glove Box Lamp 15
Glow Plug Relay BK At PDC (Diesel
Engine)
N/S
Graphic Display
Module/Vehicle
Information
Center
BK Rear of Vehicle
Information Center
(VIC)
15
Headlamp
Leveling Switch
BK At Switch 15
Headlamp Switch BK Rear of Headlamp
Switch
14
High Speed
Blower Motor
Relay
BK Right Side of HVAC N/S
Horn No. 1 BK At Horn, Lower
Right Front of
Vehicle
1
Horn No. 2 BK At Horn, Lower
Right Front of
Vehicle
1
Idle Air Control
Motor
BK On Throttle Body 5, 9
Ignition Coil BK Right Front of
Engine
5, 8
Ignition Switch BK On Steering Column 16
In-Car
Temperature
Sensor
BK Center, Top of
Instrument Panel
15
Connector
Name/Number
Color Location Fig.
Injector No. 1 GY At Injector 5, 9
Injector No. 2 GY At Injector 5, 8
Injector No. 3 GY At Injector 5, 9
Injector No. 4 GY At Injector 5, 8
Injector No. 5 GY At Injector 5, 9
Injector No. 6 GY At Injector 5, 8
Injector No. 7 GY At Injector 9
Injector No. 8 GY At Injector 8
Instrument Cluster BK Rear of Instrument
Cluster
14
Intake Air
Temperature
Sensor
GY On Intake Manifold 5, 8
Junction Block -
C1
BK Behind Kick Panel N/S
Junction Block -
C2
BK Behind Kick Panel N/S
Junction Block -
C3
BK Behind Kick Panel N/S
Junction Block -
C4
BL* Behind Kick Panel N/S
Junction Block -
C5
YL Behind Kick Panel N/S
Junction Block -
C6
GY Behind Kick Panel N/S
Junction Block -
C7
GN Behind Kick Panel N/S
Junction Block -
C8
BK Behind Kick Panel N/S
Junction Block -
C9
BK Behind Kick Panel N/S
Junction Block -
C10
BK Behind Kick Panel N/S
Junction Block
Body Connector -
C13
BK Behind Kick Panel N/S
Junction Block
Body Connector -
C14
BK Behind Kick Panel N/S
Key-In Switch/
Halo Lamp
GY On Steering
Column, Near
Ignition Switch
16
Lamp Outage
Module C1
BK Left Rear Quarter
Panel, Near Bottom
of Liftgate Opening
19
8W - 90 - 4 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
Lamp Outage
Module C2
BK Left Rear Quarter
Panel, Near Bottom
of Liftgate Opening
19
Left Back-Up
Lamp
BK At Lamp N/S
Left Courtesy
Lamp
BK At Lamp 14
Left Door
Courtesy Lamp
BK In Left Front Door 20
Left Fog Lamp BK Left Fog Lamp 1
Left Front
Cylinder Lock
Switch
BK In Left Front Door 20
Left Front Door
Lock Motor
BK In Left Front Door 20
Left Front Door
Speaker
BK In Left Front Door 20
Left Front Park
Lamp
WT At Lamp N/S
Left Front Power
Window Motor
BK In Left Front Door 20
Left Front Side
Marker Lamp
GY At Lamp N/S
Left Front Turn
Signal Lamp
BK At Lamp N/S
Left Front Wheel
Speed Sensor
BK Left Rear Corner of
Engine
Compartment
N/S
Left Headlamp BK Rear of Headlamp 1
Left Headlamp
Leveling Motor
BK At Headlamp 1
Left Instrument
Panel Speaker
BK Rear of Left
Instrument Panel
Speaker
14
Left License
Lamp
NAT In Liftgate Behind
License Plate
Lamps
25
Left Rear Door
Lock Motor
BK In Left Rear Door 21
Left Rear Door
Speaker
BK In Left Rear Door 21
Left Rear Power
Window Motor
BK In Left Rear Door 21
Left Rear Power
Window switch
BL In Left Rear Door 21
Left Rear Side
Marker Lamp
NAT At Lamp N/S
Connector
Name/Number
Color Location Fig.
Left Rear Turn
Signal Lamp
BK At Lamp N/S
Left Rear Wheel
Speed Sensor
BK Below Right Rear
Passenger Seat
18
Left Side
Repeater Lamp
BK At Lamp N/S
Left Tail/Stop
Lamp
BK At Lamp N/S
Left Visor/Vanity
Mirror
BK Top of Left A-Pillar 17
Liftgate Ajar
Switch
BK In Liftgate 23
Liftgate Cylinder
Lock Switch
BK In Liftgate 23
Liftgate Lock
Motor
BK In Liftgate 23
Liftglass Ajar
Switch
BK In Liftgate 23
Liftglass Limit
Switch
NAT In Liftgate 23
Liftglass Push
Button
BK In Liftgate 23
Liftglass Release
Solenoid
BK In Liftgate 23
Low Washer Fluid
Level Sensor
BK At Washer Reservoir 4
Manifold Absolute
Pressure Sensor
BK On Throttle Body 5, 9
Memory Seat
Module
Connector C1
BK At Drivers Seat N/S
Memory Seat
Module
Connector C2
BK At Drivers Seat N/S
Mini Overhead
Console
GY Under Front Seat N/S
Mode Door Motor BK Left Side of HVAC N/S
Multi-Function
Switch
BK On Steering Column 16
Oil Pressure
Sensor
BK Near Distributor 5, 9
Output Shaft
Speed Sensor
BK Left Side of
Transmission
7, 10
Overhead
Console
RD Center of Headliner,
Above Rear View
Mirror
17
ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 5
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
Overhead
Console Junction
Block
BK Behind Kick Panel,
At Junction Block
N/S
Park/Neutral
Position Switch
BK Left Side of
Transmission
7, 10
Passenger Airbag YL Behind Passenger
Airbag
14
Passenger Door
Module
WT In Front Door 20
Passenger
Heated Seat Back
GN Under Passengers
Seat
N/S
Passenger
Heated Seat
Cushion
BK Under Passengers
Seat
N/S
Passenger
Lumbar Motor
BK Under Passengers
Seat
N/S
Passenger
Lumbar Switch
WT Under Passengers
Seat
N/S
Passenger Power
Seat Front Riser
Motor
RD Under Passengers
Seat
N/S
Passenger Power
Seat Horizontal
Motor
BK Under Passengers
Seat
N/S
Passenger Power
Seat Rear Riser
Motor
RD Under Passengers
Seat
N/S
Passenger Power
Seat Recliner
Motor
BK Under Passengers
Front Seat
N/S
Passenger Power
Seat Switch
BK Under Passengers
Front Seat
N/S
Passenger Seat
Heater Control
Module
GY Under Passengers
Seat
N/S
Power Amplifier
C1
WT Below Right Rear
Passenger Seat
13
Power Amplifier
C2
WT Below Right Rear
Passenger Seat
13
Power Antenna
Motor
BK At Antenna N/S
Power Outlet BK Rear of Power
Outlet
14
Powertrain
Control Module
C1
BK Right Rear Corner
of Engine
Compartment At
PCM
3
Connector
Name/Number
Color Location Fig.
Powertrain
Control Module
C2
WT Right Rear Corner
of Engine
Compartment At
PCM
3
Powertrain
Control Module
C3
GY Right Rear Corner
of Engine
Compartment At
PCM
3
Radio C1 GY Rear of Radio 14
Radio C2 BK Rear of Radio 14
Radio C3 BK Rear of Radio 14
Rear Speaker BK Rear Door 21
Rear Washer
Pump Motor
BK lBottom of
Windshield Washer
Fluid Reservoir
4
Rear Wiper Motor BK In Liftgate 23
Rear Wiper/
Washer Switch
BK Behind Rear Wiper
Switch
14
Recirculation
Door Motor
YL Top of HVAC N/S
Right Back-Up
Lamp
BK At Lamp N/S
Right Courtesy
Lamp
BK Right Courtesy
Lamp
14
Right Door
Courtesy Lamp
BK In Right Front Door 20
Right Fog Lamp BK Rear of Fog Lamp 1
Right Front
Cylinder Lock
Switch
BK In Right Front Door 20
Right Front Door
Lock Motor
BK In Right Front Door 20
Right Front Door
Speaker
BK In Right Front Door 20
Right Front Park
Lamp
WT At Lamp N/S
Right Front Power
Window Motor
BK In Right Front Door 20
Right Front Side
Marker Lamp
GY At Lamp N/S
Right Front Turn
Signal Lamp
BK At Lamp N/S
Right Front Wheel
Speed Sensor
BK Right Rear Corner
of Engine
Compartment
2
Right Headlamp BK Right Fog Lamp 1
8W - 90 - 6 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Connector
Name/Number
Color Location Fig.
Right Headlamp
Leveling Motor
BK At Headlamp 1
Right Instrument
Panel Speaker
BK Top Right of
Instrument Panel
14
Right License
Lamp
NAT In Liftgate, Behind
License Plate
Lamps
25
Right Rear Door
Lock Motor
BK In Right Rear Door 21
Right Rear Door
Speaker
BK In Right Rear Door 21
Right Rear Power
Window Motor
BK In Right Rear Door 21
Right Rear Power
Window Switch
BL In Right Rear Door 21
Right Rear Side
Marker Lamp
NAT At Lamp N/S
Right Rear Turn
Signal Lamp
BK At Lamp N/S
Right Rear Wheel
Speed Sensor
RD Below Right Rear
Passenger Seat
18
Right Side
Repeater Lamp
BK At Lamp N/S
Right Tail/Stop
Lamp
BK At Lamp N/S
Right Visor/Vanity
Mirror
BK Top of Right A-Pillar 17
Seat Belt Switch BK Near Bottom of
Drivers Seat Belt
Clasp
18
Shift Interlock BK Steering Column,
On Shift Cable
N/S
Solar Sensor RD Above Glove Box 14
Speed
Proportional
Steering Control
Module
GN Behind Instrument
Panel
15
Speed
Proportional
Steering Solenoid
BK On Power Steering
Pump
4
Connector
Name/Number
Color Location Fig.
Stop Lamp Switch GY Top of Brake Pedal
Arm
15
Sunroof Control
Module
BK Rear of Sunroof N/S
Sunroof Motor BK Rear of Sun Roof N/S
Sunroof Switch NAT Center of Headliner,
Above Rear View
Mirror
17
Switch Pod BK Rear of Overdrive
Switch
N/S
Throttle Position
Sensor
BK On Throttle Body 5, 9
Trailer Tow Circuit
Breaker
BK Right Rear Quarter
Panel
22
Trailer Tow Left
Turn Relay
BK Right Rear Quarter
Panel
22
Trailer Tow Right
Turn Relay
BK Right Rear Quarter
Panel
22
Trailer Tow Stop
Lamp Relay
BK Right Rear Quarter
Panel
22
Transmission
Solenoid
Assembly
BK Left Side of
Transmission
7, 10
Underhood Lamp BK On Underside of
Hood
24
Upstream Heated
Oxygen Sensor
GY Right Front of
Transmission
10
Vehicle Speed
Control Servo
BK At Servo N/S
Vehicle Speed
Control/Horn
Switch
NAT On Steering Column 16
Vehicle Speed
Sensor
BK Rear of Transfer
Case
7, 10
Windshield
Washer Pump
Motor
BK Bottom of
Windshield Washer
Fluid Reservoir
4
Windshield Wiper
Motor
BK Center of Cowl 4
ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 7
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 8 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 9
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 10 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 11
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 12 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 13
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 14 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 15
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 16 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 17
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 18 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 19
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 20 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 21
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 22 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 23
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 24 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 25
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 26 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 27
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 28 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 29
DESCRIPTION AND OPERATION (Continued)
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8W - 90 - 30 8W - 90 CONNECTOR LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Fig. 24 Underhood Lamp
Fig. 25 License Plate Lamps
ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 31
DESCRIPTION AND OPERATION (Continued)
8W-95 SPLICE LOCATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng the
general l ocati on of the spl i ces i n thi s vehi cl e. A spl i ce
i ndex i s provi ded. Use the wi ri ng di agrams i n each
secti on for spl i ce number i denti fi cati on. Refer to the
i ndex for proper spl i ce number.
SPLICE LOCATIONS
For spl i ces that are not shown i n the fi gures i n
thi s secti on an N/S i s pl aced i n the Fi g. col umn.
Splice
Number
Location Fig.
S100 Near Power Distribution Center 1
S101 Near Battery Temperature
Sensor T/O
1
S102 Near Battery Temperature
Sensor T/O
1
S103 Near Battery Temperature
Sensor T/O
1
S104 Right Front Corner of Engine
Compartment
1
S105 Right Front Corner of Engine
Compartment
1
S106 Right Front Corner of Engine
Compartment
1
S107 Left Front Corner of Engine
Compartment
1
S108 Left Front Corner of Engine
Compartment
1
S109 Near EVAP/Purge Solenoid T/O 1
S116 Near Branch to Brake Warning
Switch
1
S117 In Branch to Brake Warning
Switch
1
S118 In Branch to Brake Warning
Switch
1
S119 Left Rear of Engine
Compartment
1
S120 Near T/O to Low Washer Fluid
Level Sensor
1
S121 Near T/O to Low Washer Fluid
Level Sensor
1
S122 Near Vehicle Speed Control
Servo T/O
1
S123 Near Vehicle Speed Control
Servo T/O
1
S124 Near Vehicle Speed Control
Servo T/O
1
S125 Near Controller, Antilock Brakes 6
Splice
Number
Location Fig.
S126 Near A/C High Pressure Switch
T/O (4.0L Engine)
1
S126 In Branch to Starter Motor (5.2L
Engine)
3
S127 Near Injector No. 3 T/O (4.0L
Engine)
2
S128 Near Injector No. 5 T/O (4.0L
Engine)
2
S128 Near T/Os for Injectors 6 and 8
(5.2L Engine)
3
S128 Near T/Os for A/C Compressor 4
S129 Rear of Engine (4.0L Engine) 2
S129 Near Injector No. 3 T/O (5.2L
Engine)
3
S129 Rear of Engine (Diesel Engine) N/S
S130 Rear of Engine (4.0L Engine) 2
S130 Near Crankshaft Position
Sensor T/O (5.2L Engine)
3
S130 Near Crankshaft Position
Sensor T/O (Diesel Engine)
4
S131 In Branch to Transmission (4.0L
Engine)
2
S131 Right Rear of Engine (5.2L
Engine)
3
S132 Near Branch to Transmission
(4.0L Engine)
2
S132 Rear of Engine (5.2L Engine) 3
S133 In Branch to Oil Pressure
Sensor and Crankshaft Position
Sensor (4.0L Engine)
2
S133 Near Injector No. 5 T/O (5.2L
Engine)
3
S134 Near Branch to Powertrain
Control Module (4.0L Engine)
2
S134 Rear of Engine (5.2L Engine) 3
ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 1
Splice
Number
Location Fig.
S134 Near Crankshaft Position
Sensor T/O (Diesel Engine)
4
S135 Near Branch to PCM (4.0L
Engine)
2
S135 Right Rear of Engine (5.2L
Engine)
3
S136 Near Injector No. 7 T/O (5.2L
Engine)
3
S136 Near Crankshaft Position
Sensor T/O (Diesel Engine)
4
S138 Near Crankshaft Position
Sensor T/O (Diesel Engine)
4
S140 Rear of Engine (Diesel Engine) 4
S141 Rear of Engine (Diesel Engine) 4
S142 Near T/Os for A/C Compressor 4
S200 Near Headlamp Switch T/O 5
S201 Near Headlamp Switch T/O 5
S202 Near Stop Lamp Switch T/O 5
S203 Near Stop Lamp Switch T/O 5
S204 Near Branch to Instrument
Cluster
5
S205 Near Branch to Instrument
Cluster
5
S206 Near Branch to Rear Window
Defogger Switch
5
S207 Near Shift Interlock T/O 5
S208 Near Branch to Shift Interlock
T/O
5
S209 Near Branch to Shift Interlock
T/O
5
S210 Near Transfer Case Illumination
Lamp T/O
5
S211 Near Branch to Graphic Display
Module/Vehicle Information
Center
5
S212 Near Passenger Airbag T/O 5
S214 Near Passenger Airbag T/O 5
S215 Near Passenger Airbag T/O 5
S216 Near Passenger Airbag T/O 5
S218 Near Passenger Airbag T/O 5
S219 Near Branch to Graphic Display
Module/Vehicle Information
Center
5
S220 Near Passenger Airbag T/O 5
S221 On HVAC Harness 7
Splice
Number
Location Fig.
S222 On HVAC Harness 7
S223 On HVAC Harness 7
S224 On HVAC Harness 7
S225 On HVAC Harness 7
S226 On HVAC Harness 7
S300 Near Left Kick Panel 6
S301 Near Left Kick Panel 6
S302 Near Left Kick Panel 6
S303 Near Branch to Floor Console 8
S304 Near Branch to Floor Console 8
S305 Near Branch to Left Rear Door 8
S306 Near Branch to Left Rear Door 8
S307 Near Branch to Left Rear Door 8
S308 Near Branch to Power Amplifier 8
S309 In Branch to Power Amplifier 8
S310 Near Branch to Power Amplifier 8
S311 Left Rear Quarter Panel 8
S312 Left Rear Quarter Panel 8
S313 Left Rear Quarter Panel 8
S314 Top of Left Rear Quarter Panel 8
S315 Top of Left Rear Quarter Panel 8
S316 Near Right Side T/O for Liftgate 9
S317 In Branch to Power Amplifier 8
S318 In Branch to Power Amplifier 8
S319 Near Branch to Right Rear
Door Ajar Switch
9
S320 In Branch to Dome/Reading
Lamp
9
S321 Between Day/Night Mirror T/O
and Right Vanity Mirror T/O
10
S322 Between Day/Night Mirror T/O
and Right Vanity Mirror T/O
10
S323 Near Day/Night Mirror T/O 10
S324 In Left Front Door, Between
Power Window Motor T/O and
Power Mirror T/O
11
S325 In Right Front Door, Near
Power Window Motor T/O
11
S326 In Right Front Door, Near
Power Window Motor T/O
11
S327 In Right Front Door, Near
Power Window Motor T/O
11
S328 In Liftgate, Near Rear Window
Defogger T/O
12
8W - 95 - 2 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Splice
Number
Location Fig.
S329 In Liftgate, Near Rear Wiper
Motor T/O
12
S330 In Factory Trailer Tow Harness,
Near Body Harness Connector
8
S331 In Factory Trailer Tow Harness,
Near Trailer Receptacle
Harness Connector
8
S332 In Liftgate, Near Left Body
Connectors
12
S333 Near T/O to Right Power Seat 9
S334 In Branch to Dome Reading
Lamp
10
S335 In Branch to Power Amplifier 8
S336 In Liftgate, Between Rear Wiper
Motor T/O and Liftgate Lock
Motor T/O
12
S400 In Left Power Seat Harness,
Near Lumbar Motor T/O
N/S
S401 In Left Power Seat Harness,
Near Riser Motor Sensor T/O
N/S
S402 In Left Power Seat Harness,
Between Riser Motor Sensor
T/O and Heated Seat Module
T/O
N/S
S403 In Left Power Seat Harness,
Near Seat Switch T/O
N/S
S404 In Right Power Seat Harness,
Near Seat Motor T/Os
N/S
S405 In Right Power Seat Harness,
Near Seat Motor T/Os
N/S
S406 In Right Power Seat Harness,
In Branch to Seat Switch
N/S
Splice
Number
Location Fig.
S407 In Left Power Seat Harness,
Near Lumbar Motor T/O
N/S
S408 Near Left Front Turn Signal
Bulb Socket
N/S
S409 Near Left Front Turn Signal
Bulb Socket
N/S
S410 Near Left Front Park Lamp Bulb
Socket
N/S
S411 In Left Tail Lamp Harness,
Between Body Connector and
Grommet
N/S
S412 In Left Tail Lamp Harness,
Between Body Connector and
Grommet
N/S
S413 Near Right Front Turn Signal
Bulb Socket
N/S
S414 Near Right Front Turn Signal
Bulb Socket
N/S
S415 Near Right Front Park Lamp
Bulb Socket
N/S
S416 In Right Tail Lamp Harness,
Between Body Connector and
Grommet
N/S
S417 In Right Tail Lamp Harness,
Between Body Connector and
Grommet
N/S
S418 In License Plate Lamp Harness 12
S419 In License Lamp Harness 12
S421 Fuse Link at PDC N/S
ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 3
DESCRIPTION AND OPERATION (Continued)
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8W - 95 - 4 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 5
DESCRIPTION AND OPERATION (Continued)
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8W - 95 - 6 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 7
DESCRIPTION AND OPERATION (Continued)
Fig. 6 Body Splices
Fig. 7 HVAC Harness Splices
8W - 95 - 8 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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8W - 95 - 8 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
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8W - 95 - 10 8W - 95 SPLICE LOCATIONS ZG
DESCRIPTION AND OPERATION (Continued)
Fig. 10 Roof Wiring Splices
Fig. 11 Front Door Harness Splices
ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 11
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 11
DESCRIPTION AND OPERATION (Continued)
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ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 13
DESCRIPTION AND OPERATION (Continued)
ENGINE
CONTENTS
page page
4. 0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. 2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5. 9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 89
ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD SERVICE INFORMATION . . . . . . . . 1
STANDARD SERVICE INFORMATION
INDEX
page page
GENERAL INFORMATION
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . 2
FORM-IN-PLACE GASKETSGASOLINE
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HONING CYLINDER BORES . . . . . . . . . . . . . . . 2
HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . 5
MEASURING WITH PLASTIGAGE . . . . . . . . . . . 3
REPAIR DAMAGED OR WORN THREADS . . . . . 4
SERVICE ENGINE ASSEMBLY
(SHORT BLOCK) . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
FORM-IN-PLACE GASKETSGASOLINE ENGINES
There are several pl aces where form-i n-pl ace gas-
kets are used on the engi ne. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when appl yi ng form-i n-pl ace gaskets.
Bead si ze, conti nui ty, and l ocati on are of great i mpor-
tance. Too-thi n a bead can resul t i n l eakage, whi l e
too much can resul t i n spi l l -over. A conti nuous bead
of the proper wi dth i s essenti al to obtai n a l eak-free
joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne area (Mopar Si l i cone Rubber
Adhesi ve Seal ant and Mopar Gasket Maker). Each
has di fferent properti es and they cannot be used
i nterchangeabl y.
MOPAR SILICONE RUBBER ADHESIVE
SEALANT
Mopar Si l i cone Rubber Adhesi ve Seal ant, nor-
mal l y bl ack i n col or, i s avai l abl e i n both three ounce
tubes and four and one-hal f ounce power tubes. Moi s-
ture i n the ai r causes the seal ant materi al to cure.
Thi s materi al i s normal l y used on fl exi bl e metal
fl anges. The regul ar tubes have a shel f l i fe of one
year and the power tubes a two year shel f l i fe, and
wi l l not properl y cure i f over-aged. Al ways i nspect
the package for the expi rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normal l y red i n col or, i s
avai l abl e i n si x-cc tubes. Thi s anaerobi c type gasket
materi al cures i n the absence of ai r when squeezed
between smooth machi ned metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. DO NOT use
on fl exi bl e metal fl anges.
SURFACE PREPARATION
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et, or other sui tabl e tool , to break the seal
between the mati ng surfaces. A fl at gasket-scraper
may al so be l i ghtl y tapped i nto the joi nt, but care
must be taken not to damage the mati ng surfaces.
Scrape or wi re brush al l gasket surfaces to remove
al l l oose materi al . I nspect stamped parts to ensure
that gasket rai l s are fl at. Fl atten rai l s wi th a ham-
mer on a fl at pl ate, i f requi red. Gasket surfaces must
be free of oi l and di rt. Be sure the ol d gasket mate-
ri al i s removed from bl i nd attachi ng hol es.
ZG ENGINE 9 - 1
GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care.
Mopar Si l i cone Rubber Adhesi ve Seal ant shoul d
be appl i ed i n a conti nuous bead approxi matel y 3 mm
(0.12 i nch) i n di ameter. Al l mounti ng hol es must be
ci rcl ed. For corner seal i ng, a 3 or 6 mm (1/8 or 1/4
i nch) drop i s pl aced i n the center of the gasket con-
tact area. Uncured seal ant may be removed wi th a
shop towel . Components shoul d be torqued i n pl ace
whi l e the seal ant i s sti l l wet to the touch (wi thi n ten
mi nutes). The use of a l ocati ng dowel i s recom-
mended duri ng assembl y to prevent smeari ng the
materi al off l ocati on.
Mopar Gasket Maker shoul d be appl i ed spari ngl y
to one gasket surface. The seal ant di ameter shoul d
be 1.00 mm (0.04 i nch) or l ess. Be certai n the mate-
ri al surrounds each mounti ng hol e. Excess materi al
can be easi l y wi ped off. Components shoul d be
torqued i n pl ace wi thi n 15 mi nutes. The use of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng the materi al off l ocati on.
ENGINE PERFORMANCE
To provi de best vehi cl e performance and l owest
vehi cl e emi ssi ons, i t i s most i mportant that the
tune-up be done accuratel y. Use the speci fi cati ons
l i sted on the Vehi cl e Emi ssi on Control I nformati on
l abel found on the engi ne compartment hood.
(1) Test battery speci fi c gravi ty. Add water, i f nec-
essary. Cl ean and ti ghten battery connecti ons.
(2) Test cranki ng amperage draw (refer to Group
8B, Battery/Starter for the proper procedure).
(3) Ti ghten the i ntake mani fol d bol ts (refer to
Group 11, Exhaust System and I ntake Mani fol d for
the proper speci fi cati ons).
(4) Perform cyl i nder compressi on test:
CAUTION: DO NOT overspeed the engine.
(a) Check engi ne oi l l evel and add oi l , i f neces-
sary.
(b) Dri ve the vehi cl e unti l engi ne reaches nor-
mal operati ng temperature.
(c) Sel ect a route free from traffi c and other
forms of congesti on, observe al l traffi c l aws and
bri skl y accel erate through the gears several ti mes.
The hi gher engi ne speed may hel p cl ean out val ve
seat deposi ts whi ch can prevent accurate compres-
si on readi ngs.
(d) Remove al l spark pl ugs from engi ne. As
spark pl ugs are bei ng removed, check el ectrodes for
abnormal fi ri ng i ndi cators - foul ed, hot, oi l y, etc.
Record cyl i nder number of spark pl ug for future
reference.
(e) Di sconnect coi l wi re from di stri butor and
secure to good ground to prevent a spark from
starti ng a fi re.
(f) Be sure throttl e bl ades are ful l y open duri ng
the compressi on check.
(g) I nsert compressi on gage adaptor i nto the
No.1 spark pl ug hol e. Crank engi ne unti l maxi -
mum pressure i s reached on gauge. Record thi s
pressure as No.1 cyl i nder pressure.
(h) Repeat for al l remai ni ng cyl i nders.
(i ) Compressi on shoul d not be l ess than 689 kPa
(100 psi ) and not vary more than 172 kPa (25 psi )
from cyl i nder to cyl i nder.
(j) I f cyl i nder(s) have abnormal l y l ow compres-
si on pressures, repeat procedure.
(k) I f the same cyl i nder(s) repeat an abnormal l y
l ow readi ng, i t coul d i ndi cate the exi stence of a
probl em i n the cyl i nder.
NOTE: The recommended compression pressures
are to be used only as a guide to diagnosing engine
problems. An engine should NOT be disassembled
to determine the cause of low compression unless
some malfunction is present.
(5) Cl ean or repl ace spark pl ugs as necessary.
Adjust gap (refer to Group 8D, I gni ti on System for
gap adjustment and torque).
(6) Test resi stance of spark pl ug cabl es (refer to
Group 8D, I gni ti on System).
(7) I nspect the pri mary wi re. Test coi l output vol t-
age, pri mary and secondary resi stance. Repl ace parts
as necessary (refer to Group 8D, I gni ti on System and
make necessary adjustment).
(8) Set i gni ti on ti mi ng to speci fi cati ons (refer to
Speci fi cati on Label on engi ne compartment hood).
(9) Perform a combusti on anal ysi s.
(10) Test fuel pump for pressure (refer to Group
14, Fuel System for the proper speci fi cati ons).
(11) I nspect ai r fi l ter el ement (refer to Group 0,
Lubri cati on and Mai ntenance for the proper proce-
dure).
(12) I nspect crankcase venti l ati on system (refer to
Group 0, Lubri cati on and Mai ntenance for the proper
procedure).
(13) For emi ssi on control s refer to Group 25, Emi s-
si on Control s System for servi ce procedures.
(14) I nspect and adjust accessory bel t dri ves (refer
to Group 7, Cool i ng System for the proper adjust-
ments).
(15) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
9 - 2 ENGINE ZG
GENERAL INFORMATION (Continued)
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823 equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round as wel l as removi ng l i ght
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). 20-60 strokes,
dependi ng on the bore condi ti on, wi l l be suffi ci ent to
provi de a sati sfactory surface. Usi ng honi ng oi l
C-3501-3880 or a l i ght honi ng oi l avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 1).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
MEASURING WITH PLASTIGAGE
CRANKSHAFT MAIN BEARING CLEARANCE
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage, or equi val ent. The fol l ow-
i ng i s the recommended procedures for the use of
Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) The total cl earance of the mai n beari ngs can
onl y be determi ned by removi ng the wei ght of the
crankshaft. Thi s can be accompl i shed by ei ther of two
methods:
METHOD - 1 (PREFERRED)
Shi m the beari ngs adjacent to the beari ng to be
checked. Thi s wi l l remove the cl earance between
upper beari ng shel l and the crankshaft. Pl ace a mi n-
i mum of 0.254 mm (0.010 i nch) shi m between the
beari ng shel l and the adjacent beari ng cap. Ti ghten
the bol ts to 18 Nm (13 ft. l bs.) torque.
ALL ENGINES When checki ng No.1 mai n
beari ng; shi m No.2 mai n beari ng.
ALL ENGINES When checki ng No.2 mai n
beari ng; shi m No.1 and No.3 mai n beari ng.
ALL ENGINES When checki ng No.3 mai n
beari ng; shi m No.2 and No.4 mai n beari ng.
ALL ENGINES When checki ng No.4 mai n
beari ng; shi m No.3 and No.5 mai n beari ng.
5.2/5.9L ENGINE When checki ng No.5 mai n
beari ng; shi m No.4 mai n beari ng.
4.0L ENGINE When checki ng No.5 mai n
beari ng; shi m No.4 and No.6 mai n beari ng.
4.0L ENGINE When checki ng No.6 mai n
beari ng; shi m No.5 and No.7 mai n beari ng.
4.0L ENGINE When checki ng No.7 mai n
beari ng; shi m No.6 mai n beari ng.
NOTE: Remove all shims before assembling
engine.
METHOD - 2 (ALTERNATIVE)
The wei ght of the crankshaft i s supported by a jack
under the counterwei ght adjacent to the beari ng
bei ng checked.
(1) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 2). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n
that area. Ti ghten the beari ng cap bol ts of the bear-
i ng bei ng checked to 108 Nm (80 ft. l bs.) torque
(4.0L Engi ne). Ti ghten the beari ng cap bol ts of the
beari ng bei ng checked to 115 Nm (85 ft. l bs.) torque
(5.2/5.9L Engi ne). DO NOT rotate the crankshaft
Fig. 1 Cylinder Bore Crosshatch Pattern
CROSSHATCH PATTERN INTERSECT ANGLE
ZG ENGINE 9 - 3
GENERAL INFORMATION (Continued)
or the Plastigage may be smeared, giving inac-
curate results.
(2) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 3). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(3) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
CONNECTING ROD BEARING CLEARANCE
Engi ne connecti ng rod beari ng cl earances can be
determi ned by use of Pl asti gage, or equi val ent. The
fol l owi ng i s the recommended procedures for the use
of Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 2). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n the
suspect area.
(3) The crankshaft must be turned unti l the con-
necti ng rod to be checked starts movi ng toward the
top of the engi ne. Onl y then shoul d the rod cap wi th
Pl asti gage i n pl ace be assembl ed. Ti ghten the 4.0L
rod cap nut to 45 Nm (33 ft. l bs.) torque. Ti ghten the
5.2/5.9L rod cap nut to 61 Nm (45 ft. l bs.) torque.
DO NOT rotate the crankshaft or the Plastigage
may be smeared, giving inaccurate results.
(4) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 2). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(5) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
REPAIR DAMAGED OR WORN THREADS
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Hel i -Coi l tool s and i nserts are readi l y avai l abl e
from automoti ve parts jobbers.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A servi ce repl acement engi ne assembl y (short
bl ock) may be i nstal l ed whenever the ori gi nal cyl i n-
der bl ock i s defecti ve or damaged beyond repai r. I t
consi sts of the cyl i nder bl ock, crankshaft, pi ston and
rod assembl i es. I f needed, the camshaft must be pro-
cured separatel y and i nstal l ed before the engi ne i s
i nstal l ed i n the vehi cl e.
A short bl ock i s i denti fi ed wi th the l etter S
stamped on the same machi ned surface where the
bui l d date code i s stamped for compl ete engi ne
assembl i es.
I nstal l ati on i ncl udes the transfer of components
from the defecti ve or damaged ori gi nal engi ne. Fol -
l ow the appropri ate procedures for cl eani ng, i nspec-
ti on and torque ti ghteni ng.
Fig. 2 Placement of Plastigage in BearingShell
PLASTIGAGE
Fig. 3 Clearance Measurement
9 - 4 ENGINE ZG
GENERAL INFORMATION (Continued)
HYDROSTATIC LOCK
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(refer to Group 14, Fuel System).
(2) Di sconnect the negati ve cabl e from the battery.
(3) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the pl ugs from the
engi ne.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (i .e. cool ant,
fuel , oi l , etc.).
(7) Make sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt engi ne oi l i nto the cyl i nders to l ubri cate
the wal l s. Thi s wi l l prevent damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the 4.0L
engi ne spark pl ugs to 37 Nm (27 ft. l bs.) torque.
Ti ghten the 5.2/5.9L engi ne spark pl ugs to 41 Nm
(30 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
Nm (25 ft. l bs.) torque.
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l .
(15) Connect the negati ve cabl e to the battery.
(16) Start the engi ne and check for any l eaks.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed or an oi l that conforms to the API Servi ce Grade
SH or SH/CD. MOPAR provi des engi ne oi l s that con-
form to al l of these servi ce grades.
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 30 speci fi es a si ngl e vi scos-
i ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range. Sel ect an engi ne oi l that i s best
sui ted to your parti cul ar temperature range and vari -
ati on (Fi g. 4).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. They are desi gnated as ei ther
ENERGY CONSERVI NG or ENERGY CONSERV-
I NG I I .
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 5).
ENGINE OIL ADDITIVES
I n some i nstances, such as i nfrequent operati on,
short tri p dri vi ng, and duri ng break-i n after a major
overhaul , addi ti on of speci al materi al s contai ni ng
anti -rust and anti -scuff addi ti ves are benefi ci al . A
sui tabl e product for thi s purpose i s MOPAR Engi ne
Oi l Suppl ement.
Fig. 4 Temperature/Engine Oil Viscosity
ANTICIPATED TEMPERATURE RANGE BEFORE NEXT OIL CHANGE
ZG ENGINE 9 - 5
GENERAL INFORMATION (Continued)
OIL LEVEL INDICATOR (DIPSTICK)
The engi ne oi l l evel i ndi cator i s l ocated at the ri ght
rear of engi ne on 4.0L engi nes (Fi g. 6) and the ri ght
front of the engi ne on 5.2/5.9L engi nes (Fi g. 7).
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine
oil, oil foaming and oil pressure loss can result.
I nspect engi ne oi l l evel approxi matel y every 800
ki l ometers (500 mi l es). Unl ess the engi ne has exhi b-
i ted l oss of oi l pressure, run the engi ne for about fi ve
mi nutes before checki ng oi l l evel . Checki ng engi ne oi l
l evel on a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck (Fi g. 8).
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng (Fi g. 8).
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
Fig. 5 Engine Oil Container Standard Notations
Fig. 6 Engine Oil Dipstick 4.0L Engine
TRANSMISION DIPSTICK
OIL FILL CAP
OIL DIPSTICK
Fig. 7 Engine Oil Dipstick 5.2/5.9L Engine
ENGINE OIL FILL-
HOLE CAP
DIPSTICK
Fig. 8 Engine Oil Dipstick4.0L Engine
DIPSTICK SAFE ADD
9 - 6 ENGINE ZG
GENERAL INFORMATION (Continued)
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
Al l engi nes are equi pped wi th a hi gh qual i ty ful l -
fl ow, di sposabl e type oi l fi l ter. Chrysl er Corporati on
recommends a Mopar or equi val ent oi l fi l ter be used.
OIL FILTER REMOVAL
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se (Fi g. 9) to
remove i t from the cyl i nder bl ock oi l fi l ter boss.
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface (Fi g. 10) of oi l and gri me.
OIL FILTER INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 10) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
Fig. 9 Oil Filter4.0L Engine
CYLINDER BLOCK ADAPTER FWD OIL FILTER
Fig. 10 Oil Filter Sealing SurfaceTypical
SEALING SUR- FACE RUBBER GAS- KET OIL FIL- TER
ZG ENGINE 9 - 7
GENERAL INFORMATION (Continued)
ENGINE DIAGNOSIS
INDEX
page page
DIAGNOSIS AND TESTING
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 9
CYLINDER COMPRESSION PRESSURE TEST . 8
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . 11
ENGINELUBRICATION . . . . . . . . . . . . . . . . . 14
ENGINEMECHANICAL . . . . . . . . . . . . . . . . . 13
ENGINEPERFORMANCE . . . . . . . . . . . . . . . 12
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 8
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 10
INSPECTION (ENGINE OIL LEAKS IN
GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . 8
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne tune-ups.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
Refer to the Servi ce Di agnosi sPerformance chart
and the Servi ce Di agnosi sMechani cal chart for pos-
si bl e causes and correcti ons of mal functi ons. Refer to
Group 14, Fuel System for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
Cyl i nder Compressi on Pressure Test.
Cyl i nder Combusti on Pressure Leakage Test.
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s.
I ntake Mani fol d Leakage Di agnosi s.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
CYLINDER COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sconnect the i gni ti on coi l .
(5) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(6) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
Refer to Engi ne Speci fi cati ons for the correct
engi ne compressi on pressures.
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS
A l eaki ng engi ne cyl i nder head gasket usual l y
resul ts i n l oss of power, l oss of cool ant and engi ne
mi sfi ri ng.
An engi ne cyl i nder head gasket l eak can be l ocated
between adjacent cyl i nders or between a cyl i nder and
the adjacent water jacket.
An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders i s i ndi cated by a l oss of power
and/or engi ne mi sfi re.
An engi ne cyl i nder head gasket l eaki ng between
a cyl i nder and an adjacent water jacket i s i ndi cated
by cool ant foami ng or overheati ng and l oss of cool ant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders; fol l ow the proce-
9 - 8 ENGINE ZG
dures outl i ned i n Cyl i nder Compressi on Pressure
Test. An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders wi l l resul t i n approxi matel y a
50-70% reducti on i n compressi on pressure.
CYLINDER-TO-WATER J ACKET LEAKAGE
TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Remove the radi ator cap.
Start the engi ne and al l ow i t to warm up unti l the
engi ne thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
I f bubbl es are not vi si bl e, i nstal l a radi ator pres-
sure tester and pressuri ze the cool ant system.
I f a cyl i nder i s l eaki ng combusti on pressure i nto
the water jacket, the tester poi nter wi l l pul sate wi th
every combusti on stroke of the cyl i nder.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(3) Remove the spark pl ugs.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1 379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to the Cyl i nder Combusti on Pressure Leak-
age Test Di agnosi s chart.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begi n wi th a through vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODY
INTAKE VALVE BENT, BURNT, OR
NOT SEATED PROPERLY
INSPECT VALVE. REFACE OR
REPLACE, AS NECESSARY
AIR ESCAPES THROUGH
TAILPIPE
EXHAUST VALVE BENT, BURNT,
OR NOT SEATED PROPERLY
INSPECT VALVE. REFACE OR
REPLACE, AS NECESSARY
AIR ESCAPES THROUGH
RADIATIOR
HEAD GASKET LEAKING OR
CRACKED CYLINDER HEAD OR
BLOCK
REMOVE CYLINDER HEAD AND
INSPECT. REPLACE DEFECTIVE
PART
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
HEAD GASKET LEAKING OR
CRACK IN CYLINDER HEAD OR
BLOCK BETWEEN ADJACENT
CYLINDERS
REMOVE CYLINDER HEAD AND
INSPECT. REPLACE GASKET,
HEAD, OR BLOCK AS
NECESSARY
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
STUCK OR BROKEN PISTON
RINGS; CRACKED PISTON;
WORN RINGS AND/OR
CYLINDER WALL
INSPECT FOR BROKEN RINGS
OR PISTON. MEASURE RING GAP
AND CYLINDER DIAMETER,
TAPER AND OUT-OF-ROUND.
REPLACE DEFECTIVE PART AS
NECESSARY
ZG ENGINE 9 - 9
DIAGNOSIS AND TESTING (Continued)
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.
(5) If the oil leak source is not positively
identified at this time , proceed wi th the ai r l eak
detecti on test method.
Air Leak Detec tion Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(1) Di sconnect the battery.
(2) Rai se the vehi cl e.
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
HYDRAULIC TAPPETS
Before di sassembl i ng any part of the engi ne to cor-
rect tappet noi se, check the oi l pressure. I f vehi cl e
has no oi l pressure gauge, i nstal l a rel i abl e gauge at
the pressure sendi ng-uni t. The pressure shoul d be
between 207-552 kPa (30-80 psi ) at 3,000 RPM.
Check the oi l l evel after the engi ne reaches normal
operati ng temperature. Al l ow 5 mi nutes to stabi l i ze
oi l l evel , check di psti ck. The oi l l evel i n the pan
shoul d never be above the FULL mark or bel ow the
ADD OI L mark on di psti ck. Ei ther of these two con-
di ti ons coul d be responsi bl e for noi sy tappets.
OIL LEVEL
HIGH
I f oi l l evel i s above the FULL mark, i t i s possi bl e
for the connecti ng rods to di p i nto the oi l . Wi th the
engi ne runni ng, thi s condi ti on coul d create foam i n
the oi l pan. Foam i n oi l pan woul d be fed to the
hydraul i c tappets by the oi l pump causi ng them to
l ose l ength and al l ow val ves to seat noi si l y.
LOW
Low oi l l evel may al l ow oi l pump to take i n ai r.
When ai r i s fed to the tappets, they l ose l ength,
9 - 10 ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
whi ch al l ows val ves to seat noi si l y. Any l eaks on
i ntake si de of oi l pump through whi ch ai r can be
drawn wi l l create the same tappet acti on. Check the
l ubri cati on system from the i ntake strai ner to the
pump cover, i ncl udi ng the rel i ef val ve retai ner cap.
When tappet noi se i s due to aerati on, i t may be
i ntermi ttent or constant, and usual l y more than one
tappet wi l l be noi sy. When oi l l evel and l eaks have
been corrected, operate the engi ne at fast i dl e. Run
engi ne for a suffi ci ent ti me to al l ow al l of the ai r
i nsi de the tappets to be bl ed out.
TAPPET NOISE DIAGNOSIS
(1) To determi ne source of tappet noi se, operate
engi ne at i dl e wi th cyl i nder head covers removed.
(2) Feel each val ve spri ng or rocker arm to detect
noi sy tappet. The noi sy tappet wi l l cause the affected
spri ng and/or rocker arm to vi brate or feel rough i n
operati on.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Val ve tappet noi se ranges from l i ght noi se to a
heavy cl i ck. A l i ght noi se i s usual l y caused by exces-
si ve l eak-down around the uni t pl unger, or by the
pl unger parti al l y sti cki ng i n the tappet body cyl i nder.
The tappet shoul d be repl aced. A heavy cl i ck i s
caused by a tappet check val ve not seati ng, or by for-
ei gn parti cl es wedged between the pl unger and the
tappet body. Thi s wi l l cause the pl unger to sti ck i n
the down posi ti on. Thi s heavy cl i ck wi l l be accompa-
ni ed by excessi ve cl earance between the val ve stem
and rocker arm as val ve cl oses. I n ei ther case, tappet
assembl y shoul d be removed for i nspecti on and cl ean-
i ng.
(4) The val ve trai n generates a noi se very much
l i ke a l i ght tappet noi se duri ng normal operati on.
Care must be taken to ensure that tappets are mak-
i ng the noi se. I f more than one tappet seems to be
noi sy, i ts probabl y not the tappets.
ENGINE OIL PRESSURE
(1) Remove oi l pressure sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292. Start engi ne and record pressure. Refer to
Oi l Pressure i n Engi ne Speci fi cati ons for the proper
pressures.
ZG ENGINE 9 - 11
DIAGNOSIS AND TESTING (Continued)
ENGINEPERFORMANCE
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT
START
1. Weak battery. 1. Test battery specific gravity. Charge or replace as necessary.
2. Corroded or looose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral
grease to the terminals.
3. Faulty starter. 3. Refer to Group 8A, Battery/Starter/Charging System Diagnostics.
4. Moisture on ignition wires and distributor
cap.
4. Wipe wires and cap clean and dry.
5. Faulty ignition cables. 5. Replace any cracked or shorted cables.
6. Faulty coil or control unit. 6. Test and replace, if necessary (refer to Group 8D, Ignition System).
7. Incorrect spark plug gap. 7. Set gap (refer to Group 8D, Ignition System).
8. Incorrect ignition timing. 8. Refer to Group 8D, Ignition System.
9. Dirt or water in fuel system. 9. Clean system and replace fuel filter.
10. Faulty fuel pump, relay or wiring. 10. Refer to Group 14, Fuel System.
ENGINE STALLS OR
ROUGH IDLE
1. Idle speed set too low. 1. Refer to Group 14, Fuel System.
2. Idle mixture too lean or too rich. 2. Refer to Group 14, Fuel System.
3. Leak in intake manifold. 3. Inspect intake manifold gasket and vacuum hoses. Replace, if
necessary (refer to Group 11, Exhaust System & Intake Manifold).
4. Worn or burned distributor rotor. 4. Install new distributor rotor.
5. Incorrect ignition wiring. 5. Install correct wiring.
6. Faulty coil. 6. Test and replace, if necessary (refer to Group 8D, Ignition System).
7. EGR valve leaking. 7. Test and replace, if necessary (refer to Group 25, Emissions Control
System).
8. Incorrect cam timing. 8. Refer to Timing Belt Service.
ENGINE LOSS OF
POWER
1. Incorrect ignition timing. 1. Refer to Group 8D, Ignition System.
2. Worn or burned distributor rotor. 2. Install new distributor rotor.
3. Worn distributor shaft. 3. Remove and repair distributor (refer to Group 8D, Ignition System).
4. Dirty or incorrectly gapped spark plugs. 4. Clean plugs and set gap (refer to Group 8D, Ignition System).
5. Dirt or water in fuel system. 5. Clean system and repalce fuel filter.
6. Faulty fuel pump. 6. Install new fuel pump.
7. Incorrect valve timing. 7. Correct valve timing.
8. Blown cylinder head gasket. 8. Install new cylinder head gasket.
9. Low compression. 9. Test compression of each cylinder.
10. Burned, warped or pitted valves. 10. Install new valves.
11. Plugged or restricted exhaust system. 11. Install new parts, as necessary.
12. Faulty ignition cables. 12. Replace any cracked or shorted cables.
13. Faulty coil. 13. Test and replace, as necessary (refer to Group 8D, Ignition System.)
14. Incorrect cam timing. 14. Refer to Timing Belt Service.
ENGINE MISSES ON
ACCELERATION
1. Dirty or gap sets too wide in spark plug. 1. Clean spark plugs and set gap (refer to Group 8D, Ignition System).
2. Incorrect ignition timing. 2. Refer to Group 8D, Ignition System.
3. Dirt in fuel system. 3. Clean fuel system.
4. Burned, warped or pitted valves. 4. Install new valves.
5. Faulty coil. 5. Test and replace, if necessary, (refer to Group 8D, Ignition System).
6. Incorrect cam timing. 6. Refer to Timing Belt Service.
ENGINE MISSES AT
HIGH SPEED
1. Dirty or gap set too wide in spark plug. 1. Clean spark plugs and set gap (refer to Group 8D, Ignition System).
2. Worn distributor shaft. 2. Remove and repair distributor (refer to Group 8D, Ignition System).
3. Worn or burned distributor rotor. 3. Install new distributor rotor.
4. Faulty coil. 4. Test and replace, as necessary (refer to Group 8D, Ignition System).
5. Incorrect ignition timing. 5. Refer to Group 8D, Ignition System.
6. Dirty injector in throttle body. 6. Clean injector.
7. Dirt or water in fuel system. 7. Clean system and replace fuel filter.
8. Incorrect cam timing. 8. Refer to Timing Belt Service.
9 - 12 ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
ENGINEMECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.
1. Check for correct oil level (refer to Group
0, Lubrication and Maintenance.)
2. Thin or diluted oil. 2. Change oil (refer to Group 0, Lubrication
and Maintenance).
3. Low oil pressure. 3. Check engine oil level.
4. Dirt in tappets/lash
adjusters.
4. Clean hydraulic tappets/hydraulic lash
adjusters.
5. Bent push rods. 5. Install new push rods.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn tappets/lash
adjusters.
7. Install new hydraulic tappets/hydraulic lash
adjusters.
8. Worn valve guides. 8. Ream and install new valves with oversize
stems.
9. Excessive runout of valve
seats on valve faces.
9. Grind valve seats and valves.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to Group 0,
Lubrication and Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil pump
relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing
clearance.
4. Measure bearings for correct clearance.
Repair as necessary.
5. Connecting rod journal
out-of-round.
5. Replace crankshaft or grind journals.
6. Misaligned connecting
rods.
6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to Group 0,
Lubrication and Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil pump
relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing
clearance.
4. Measure bearings for correct clearance.
Repair as necessary.
5. Excessive end play. 5. Check No. 3 main bearing for wear on
flanges.
6. Crankshaft journal
out-of-round, worn.
6. Grind journals or replace crankshaft.
7. Loose flywheel or torque
converter.
7. Tighten to correct torque.
ZG ENGINE 9 - 13
DIAGNOSIS AND TESTING (Continued)
ENGINELUBRICATION
CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned, deteriorated or torn. (a) Replace the part.
(b) Loose fastener, broken or porous
metal part.
(b) Tighten, repair or replace the part.
2. Crankshaft Rear Seal 2.
(a) Misinstalled, inverted or torn lip (a) Replace the seal.
(b) Torn, cut or shaved seal back
bead.
(b) Replace the seal.
3. Crankshaft Seal Flange. 3.
Scratched, nicked or grooved. Replace or polish if necessary.
4. Cylinder block to Cap Mating
Surface.
4.
(a) Inadequate Loctite sealant. (a) Apply sealant per service manual
procedures.
(b) Oil hole burr. (b) Carefully stone or chamfer hole.
5. Oil Pan to Rear Main Cap Sealant 5.
(Slots 3.9 - 5.2 only).
(a) Inadequate or mislocated sealant. (a) Apply sealant per service manual
procedures.
(b) Torn, cut or misinstalled oil pan. (b) Replace the gasket.
(c) Cracked or damaged oil pan
flange.
(c) Replace the oil pan.
6. Chain Case Cover Seal 6.
(a) Misinstalled, cocked or misaligned (a) Replace per service manual procedures.
(b) Torn, cut or damaged seal lips. (b) Replace the seal.
(c) Scratched or damaged seal casing
or cover bore.
(c) Replace the seal.
(d) Scratched or damaged vibration
damper hub.
(d) Minor damage can be polished out;
otherwise replace the part.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and check main bearing
oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Excessive bearing clearance. 7. Measure bearings for correct clearance.
8. Oil pump relief valve stuck. 8. Remove valve and inspect, clean and install.
9. Oil pump suction tube loose; bent
or cracked.
9. Remove oil pan and install new tube, if
necessary.
10. Oil pump cover warped or
cracked.
10. Install new oil pump.
OIL PUMPING AT RINGS;
SPARK PLUGS FOULING
1. Worn, scuffed or broken rings. 1. Hone cylinder bores and install new rings.
2. Carbon in oil ring slot. 2. Install new rings.
3. Rings fitted too tightly in grooves. 3. Remove the rings. Check grooves. If grooves
are not proper width, replace piston.
4. Worn valve guides. 4. Ream guides and replace valves with
oversize valves and seals.
5. Leaking intake gasket (3.9L & 5.2L
engines).
5. Replace gasket and tighten intake manifold
to proper torque.
6. Leaking valve guide seals (3.9L &
5.2L engines).
6. Replace seals.
7. Dislodged valve guide seals (3.9L &
5.2L engines).
7. Seat valve guide seals or replace, as
needed.
9 - 14 ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
4.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . 15
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . 16
OIL PUMP PRESSURE . . . . . . . . . . . . . . . . . . . 16
OVERSIZE AND UNDERSIZE COMPONENT
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE PROCEDURES
FITTING CONNECTING ROD BEARINGS . . . . . 21
FITTING CRANKSHAFT MAIN BEARINGS . . . . 23
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . 18
PISTON RING FITTING . . . . . . . . . . . . . . . . . . 19
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL AND INSTALLATION
CAMSHAFT PIN REPLACEMENT . . . . . . . . . . . 39
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . 41
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 28
ENGINE CYLINDER HEAD COVER . . . . . . . . . 30
ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . . 32
ENGINE MOUNTSFRONT . . . . . . . . . . . . . . . 27
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . 27
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 35
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
PISTONS AND CONNECTING RODS . . . . . . . . 43
REAR MAIN OIL SEALS . . . . . . . . . . . . . . . . . . 45
ROCKER ARMS AND PUSH RODS . . . . . . . . . 31
TIMING CASE COVER OIL SEAL . . . . . . . . . . . 46
TIMING CASE COVER . . . . . . . . . . . . . . . . . . . 36
TIMING CHAIN AND SPROCKETS . . . . . . . . . . 37
VALVE STEM SEAL AND SPRING . . . . . . . . . . 32
VALVES AND VALVE SPRINGS . . . . . . . . . . . . 34
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . 35
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 48
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 46
CLEANING AND INSPECTION
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 50
ENGINE CYLINDER HEAD COVER . . . . . . . . . 49
ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . . 49
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 49
ROCKER ARMS AND PUSH RODS . . . . . . . . . 49
SPECIFICATIONS
4.0L ENGINE SPECIFICATIONS . . . . . . . . . . . . 51
SPECIAL TOOLS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 54
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION
The 4.0 Li ter (242 CI D) si x-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne.
Engi ne Type . . . . . . . . . . . . . . . . . I n-l i ne 6 Cyl i nder
Bore and Stroke . 98.4 x 86.69 mm (3.88 x 3.413 i n.)
Di spl acement . . . . . . . . . . . . . . . . . . 4.0 (242 cu. i n.)
Compressi on Rati o . . . . . . . . . . . . . . . . . . . . . . 8.7:1
Torque . . . . . . . . . 305 Nm (225 ft. l bs.) @ 4000 rpm
Fi ri ng Order . . . . . . . . . . . . . . . . . . . . 153624
Lubri cati on . . . . Pressure FeedFul l Fl ow Fi l trati on
Engi ne Oi l Capaci ty . . . . . . . . . . . . 5.7 L (6 Quarts)
Cool i ng System . . Li qui d Cool edForced Ci rcul ati on
Cool i ng System Capaci ty . . . . . . . 11.4 L (12 Quarts)
Cyl i nder Bl ock . . . . . . . . . . . . . . . . . . . . . . Cast I ron
Crankshaft . . . . . . . . . . . . . . . . . Cast Nodul ar I ron
Cyl i nder Head . . . . . . . . . . . . . . . . . . . . . . Cast I ron
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . Cast I ron
Pi stons . . . . . . . . . . . . . . . . . . . . . . Al umi num Al l oy
Combusti on Chamber . . . . . . . . . . . . Doubl e Quench
Connecti ng Rods . . . . . . . . . . . . . . . . . . . . Cast I ron
Thi s engi ne i s desi gned for unl eaded fuel .
The engi ne cyl i nder head has dual quench-type
combusti on chambers that create turbul ence and fast
burni ng of the ai r/fuel mi xture. Thi s resul ts i n good
fuel economy.
The cyl i nders are numbered 1 through 6 from front
to rear. The fi ri ng order i s 1-5-3-6-2-4 (Fi g. 1).
Fig. 1 Engine Firing Order
FIRING ORDER: 1 5 3 6 2 4 CLOCKWISE ROTATION FRONT
ZG 4. 0L ENGINE 9 - 15
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n seven mai n beari ngs. The camshaft rotates
wi thi n four beari ngs.
BUILD DATE CODE
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.2 and No.3 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
1st Di gi tThe year (7 = 1997).
2nd & 3rd Di gi tsThe month (01 - 12).
4th & 5th Di gi tsThe engi ne type/fuel system/
compressi on rati o (MX = A 4.0 Li ter (242 CI D) 8.7:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
6th & 7th Di gi tsThe day of engi ne bui l d (01 -
31).
(1) FOR EXAMPLE: Code * 701MX12 * i denti -
fi es a 4.0 Li ter (242 CI D) engi ne wi th a mul ti -poi nt
fuel i njecti on system, 8.7:1 compressi on rati o and
bui l t on January 12, 1997.
LUBRICATION SYSTEM
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng. The pump draws oi l through the
screen and i nl et tube from the sump at the rear of
the oi l pan. The oi l i s dri ven between the dri ve and
i dl er gears and pump body, then forced through the
outl et to the bl ock. An oi l gal l ery i n the bl ock chan-
nel s the oi l to the i nl et si de of the ful l fl ow oi l fi l ter.
After passi ng through the fi l ter el ement, the oi l
passes from the center outl et of the fi l ter through an
oi l gal l ery that channel s the oi l up to the mai n gal -
l ery whi ch extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan.
OIL PUMP PRESSURE
The MI NI MUM oi l pump pressure i s 89.6 kPa (13
psi ) at 600 rpm. The MAXI MUM oi l pump pressure
i s 517 kPa (75 psi ) at 1600 rpm or more.
Fig. 2 Build Date Code Location
NO. 3 CYL- INDER NO. 2 CYL- INDER DAY MACHINED SURFACE MONTH YEAR
9 - 16 4. 0L ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
Oil Lubrication System
OIL GALLERY CAMSHAFT BEARING NUMBER 1 CAMSHAFT BEARING JOURNAL CAMSHAFT SPROCKET
ZG 4. 0L ENGINE 9 - 17
DESCRIPTION AND OPERATION (Continued)
OVERSIZE AND UNDERSIZE COMPONENT CODES
Some engi nes may be bui l t wi th oversi ze or under-
si ze components such as:
Oversi ze cyl i nder bores.
Oversi ze camshaft beari ng bores.
Undersi ze crankshaft mai n beari ng journal s.
Undersi ze connecti ng rod journal s.
These engi nes are i denti fi ed by a l etter code (Fi g.
3) stamped on a boss between the i gni ti on coi l and
the di stri butor (Fi g. 4).
SERVICE PROCEDURES
VALVE TIMING
Di sconnect the spark pl ug wi res and remove the
spark pl ugs.
Remove the engi ne cyl i nder head cover.
Remove the capscrews, bri dge and pi vot assembl y,
and rocker arms from above the No.1 cyl i nder.
Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
Rotate the crankshaft unti l the No.6 pi ston i s at
top dead center (TDC) on the compressi on stroke.
Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90.
I nstal l a di al i ndi cator on the end of the No.1 cyl -
i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
Set the di al i ndi cator poi nter at zero.
Rotate the crankshaft cl ockwi se (vi ewed from the
front of the engi ne) unti l the di al i ndi cator poi nter
i ndi cates 0.305 mm (0.012 i nch) travel di stance (l i ft).
The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
I f the ti mi ng notch i s more than 13 mm (1/2 i nch)
away from the TDC mark i n ei ther di recti on, the
val ve ti mi ng i s i ncorrect.
I f the val ve ti mi ng i s i ncorrect, the cause may be a
broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
PISTON FITTING
BORE GAGE METHOD
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm (
.0001 i n.) I NCREMENTS i s requi red. I f a bore gauge
i s not avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 6).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
Fig. 3 Oversize and Undersize ComponentCodes
Fig. 4 Oversize and Undersize ComponentCode
Location
LETTER CODE DISTRIBUTOR BOSS IGNITION COIL
9 - 18 4. 0L ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 5). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. . To correctl y sel ect
the proper si ze pi ston, a cyl i nder bore gauge capabl e
of readi ng i n 0.003 mm ( .0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
PISTON SIZE CHART
CYLINDER PISTON
BORE LETTER
SIZE SIZE
98.438 to 98.448 mm (3.8755 to 3.8759 i n.) . . . . . . A
98.448 to 98.458 mm (3.8759 to 3.8763 i n.) . . . . . . B
98.458 to 98.468 mm (3.8763 to 3.8767 i n.) . . . . . . C
98.468 to 98.478 mm (3.8767 to 3.8771 i n.) . . . . . . D
98.478 to 98.488 mm (3.8771 to 3.8775 i n.) . . . . . . E
98.488 to 98.498 mm (3.8775 to 3.8779 i n.) . . . . . . F
PISTON RING FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 7) (Fi g. 8). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
Fig. 5 Moly Coated Piston
DO NOT MEASURE MOLY COATED PISTON
MOLY COATED
Fig. 6 Bore Gauge
FRONT BORE GAUGE CYLINDERBORE
49.5 MM (115/16 in)
Fig. 7 Piston Dimensions
GROOVE HEIGHT A 1.5301.555 MM (0.06020.0612 in) B 4.0354.060 MM (0.15890.1598 in)
ZG 4. 0L ENGINE 9 - 19
SERVICE PROCEDURES (Continued)
Ring Side Clearance Measurement
Top Compressi on Ri ng . . . . . . . . . 0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Second Compressi on Ri ng . . . . . . 0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Oi l Control Ri ng . . . . . . . . . . . . . . . 0.06 to 0.21 mm
(0.0024 to 0.0083 i n.)
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 9).
Ring Gap Measurement
Top Compressi on Ri ng . . . . . . . . . 0.229 to 0.610 mm
(0.0090 to 0.0240 i nch)
Second Compari son Ri ng . . . . . . . 0.483 to 0.965 mm
(0.0190 to 0.0380 i nch)
Oi l Control Ri ng . . . . . . . . . . . . . 0.254 to 1.500 mm
(0.010 to 0.060 i nch)
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 10).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 11).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 11) (Fi g.
13).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Fig. 8 Ring Side Clearance Measurement
FEELERGAUGE
Fig. 9 Gap Measurement
FEELER GAUGE
Fig. 10 Top Compression ringidentification
TOP COMPRESSION RING
Fig. 11 Second Compression Ring Identification
SECOND COMPRESSION RING
CHAMFER
9 - 20 4. 0L ENGINE ZG
SERVICE PROCEDURES (Continued)
Ring Gap Orientation
Posi ti on the gaps on the pi ston as shown (Fi g.
14).
Oi l spacer - Gap on center l i ne of pi ston ski rt.
Oi l rai l s - gap 180 apart on centerl i ne of pi ston
pi n bore.
No. 2 Compressi on ri ng - Gap 180 from top oi l
rai l gap.
No. 1 Compressi on ri ng - Gap 180 from No. 2
compressi on ri ng gap.
FITTING CONNECTING ROD BEARINGS
INSPECTION
BEARINGS
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 15) (Fi g. 16). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 17). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
CONNECTING RODS
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
Fig. 12 Compression Ring Chamfer Location
TOP COMPRESSION RING SECOND COMPRES- SION RING PISTON CHAMFER
Fig. 13 Compression Ring Installation
COMPRESSION RING RING EXPANDER RECOMMENDED
Fig. 14 Ring Gap Orientation
TOP COMPRESSION RING
BOTTOM COMPRESSION RING
Fig. 15 Connecting Rod Bearing Inspection
UPPER MATING EDGES GROOVES CAUSED BY ROD BOLTS SCRATCHING JOURNAL DURING INSTALLATION WEAR PATTERN ALWAYS GREATER ON UPPER BEARING LOWER
ZG 4. 0L ENGINE 9 - 21
SERVICE PROCEDURES (Continued)
BEARING-TO-JOURNAL CLEARANCE
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
duri ng i nstal l ati on.
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
18). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 Nm (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to- journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 19). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance (refer to
Connecti ng Rod Beari ng Fi tti ng Chart).
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
Fig. 16 Locking Tab Inspection
ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS NOT FULLY SEATED OR BEING BENT
Fig. 17 Scoring Caused by Insufficient Lubricationor
by Damaged Crankshaft Pin Journal
LOWER UPPER
Fig. 18 Rod and Piston Assembly Installation
Fig. 19 Measuring Bearing Clearance withPlastigage
PLASTIGAGE SCALE COMPRESSED PLASTIGAGE
9 - 22 4. 0L ENGINE ZG
SERVICE PROCEDURES (Continued)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 45 Nm (33 ft. l bs.) torque.
SIDE CLEARANCE MEASUREMENT
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange. Refer to
Engi ne Speci fi cati ons for the proper cl earance.
Repl ace the connecti ng rod i f the si de cl earance i s
not wi thi n speci fi cati on.
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 20).
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FITTING BEARINGS (CRANKSHAFT
INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 7 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
CONNECTING ROD BEARING FITTING CHART
Fig. 20 Main Bearing Wear Patterns
UPPER INSERT NO WEAR IN THIS AREA LOW AREA IN BEAR- ING LINING HEAVIER WEAR PATTERN ON LOWER INSERT LOWER INSERT
ZG 4. 0L ENGINE 9 - 23
SERVICE PROCEDURES (Continued)
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark (Fi g. 21) on the
adjacent cheek or counterwei ght towards the rear of
the crankshaft (fl ange end). The rear mai n journal , i s
i denti fi ed by a col or-coded pai nt mark on the crank-
shaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size (Fig. 22).
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, pro-
ceed to Crankshaft Mai n Beari ngI nstal l ati on.
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
Nm (80 ft. l bs.) torque.
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 23). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
ceed to Crankshaft Mai n Beari ngI nstal l ati on.
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
Fig. 21 Crankshaft Journal Size Paint I.D.Location
NO. 7 MAIN JOURNAL SIZE PAINT MARK
NO.6 CONNECTING ROD JOURNAL SIZE PAINT MARK
Fig. 22 Bearing Insert Pairs
9 - 24 4. 0L ENGINE ZG
SERVICE PROCEDURES (Continued)
The cl earance i ndi cate wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
Repl ace the crankshaft or gri nd to accept the
appropri ate undersi ze beari ng i nserts i f:
Journal di ameters 1 through 6 are l ess than
63.4517 mm (2.4981 i nches)
Journal 7 di ameter i s l ess than 63.4365 mm
(2.4975 i nches).
Once the proper cl earances have been obtai ned,
proceed to Crankshaft Mai n Beari ngI nstal l ati on.
MAIN BEARING J OURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock
(refer to Cyl i nder Bl ock - Di sassembl e).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock (refer
to Cyl i nder Bl ock - Assembl e and Crankshaft Mai n
Beari ngs - I nstal l ati on).
Fig. 23 Measuring Bearing Clearance withPlastigage
PLASTIGAGE SCALE COMPRESSED PLASTIGAGE
ZG 4. 0L ENGINE 9 - 25
SERVICE PROCEDURES (Continued)
MAIN BEARING FITTING CHART
Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow 63.5025 -63.4898 mm Yellow - Standard Yellow - Standard
(2.5001 - 2.4996 in.)
Orange 63.4898 - 63.4771 mm Yellow - Standard Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0015 in.)
Undersize
Blue 63.4771 - 63.4644 mm Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
Green 63.4644 - 63.4517 mm Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
Red 63.2485 - 63.2358 mm Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
Crankshaft Journal #7 Only Corresponding Bearing Insert
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow 63.4873 - 63.4746 mm Yellow - Standard Yellow - Standard
(2.4995 - 2.4990 in.)
Orange 63.4746 - 63.4619 mm Yellow - Standard Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue 63.4619 - 63.4492 mm Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4985 - 2.4980 in.)
0.0254 mm (0.001 in.)
Undersize
Green 63.4492 - 63.4365 mm Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4980 - 2.4975 in.)
0.0381 mm (0.0015 in.)
Undersize
Red 63.2333 - 63.2206 mm Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4895 - 2.4890 in.)
0.254 mm (0.010 in.)
Undersize
9 - 26 4. 0L ENGINE ZG
SERVICE PROCEDURES (Continued)
REMOVAL AND INSTALLATION
ENGINE MOUNTSFRONT
The front mounts support the engi ne at each si de.
These i nsul ators are made of resi l i ent rubber.
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Support the engi ne.
(3) Rai se the vehi cl e.
(4) Remove the i nsul ator assembl y-to-l ower front
si l l bol ts (Fi g. 24) (Fi g. 25).
(5) Rai se the engi ne sl i ghtl y.
(6) Remove the thru-bol t nut and thru-bol t (Fi g.
24) (Fi g. 25). Remove the i nsul ator.
(7) I f requi red, remove the engi ne bracket from the
bl ock (Fi g. 24) (Fi g. 25).
INSTALLATION
(1) I f removed, i nstal l the engi ne bracket to the
bl ock (Fi g. 24) (Fi g. 25). Ti ghten the bol ts to 61 Nm
(45 ft. l bs.) torque.
(2) I nstal l the i nsul ator assembl y to the l ower
front si l l . Ti ghten the bol ts to 65 Nm (48 ft. l bs.)
torque.
(3) Wi th the engi ne i nsul ator assembl y and engi ne
bracket i n posi ti on, i nstal l the thru-bol t and nut (Fi g.
24) (Fi g. 25). Ti ghten the thru- bol t nut to 121 Nm
(89 ft. l bs.) torque.
(4) Lower the vehi cl e.
(5) Remove the engi ne support.
(6) Connect the negati ve cabl e to the battery.
ENGINE MOUNTREAR
A resi l i ent rubber cushi on bracket assembl y sup-
ports the transmi ssi on at the rear. Thi s bracket i s
attached to the crossmember (Fi g. 26) (Fi g. 27).
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the bol ts hol di ng the mount assy. to
the crossmember.
Fig. 24 Front Engine MountRight Side
RIGHT INSULATOR ASSEMBLY INSULATOR THRU-BOLT ENGINE BRACKET RIGHT SIDE
Fig. 25 Front Engine MountLeft Side
ENGINE BRACKET LEFT SIDE LEFT INSULATOR ASSEMBLY INSULATOR THRU-BOLT
Fig. 26 Rear Engine Mount(4x2)
TRANS. ASSY.
BRACKET
CROSSMEMBER
ZG 4. 0L ENGINE 9 - 27
(4) Rai se the transmi ssi on SLI GHTLY.
(5) Remove the thru-bol t and nut. Remove the rear
mount assy (Fi g. 26) (Fi g. 27).
(6) I f necessary, remove the bol ts hol di ng the rear
mount bracket to the transmi ssi on. Remove the
bracket from the exhaust pi pe hanger. Remove the
bracket.
INSTALLATION
(1) Posi ti on the rear mount bracket onto the
exhaust hanger (i f previ ousl y removed). Posi ti on the
rear mount bracket assembl y onto the transmi ssi on
and i nstal l the bol ts. Ti ghten the bol ts to 46 Nm (34
ft. l bs.)
(2) Posi ti on mount i nto mount bracket and i nstal l
thru-bol t and nut. DO NOT ti ghten the bol t at thi s
ti me.
(3) Lower the transmi ssi on unti l the mount fasten-
i ng studs are i n posi ti on i n the crossmember.
(4) Remove the transmi ssi on support.
(5) I nstal l the mount fasteni ng nuts and ti ghten
the nuts to 54 Nm (40 ft. l bs.) torque.
(6) Ti ghten the thru-bol t nut to 65 Nm (48 ft. l bs.)
torque.
(7) Lower the vehi cl e.
(8) Connect the negati ve cabl e to the battery.
ENGINE ASSEMBLY
REMOVAL
(1) Di sconnect the battery cabl es. Remove the bat-
tery.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
(3) Remove the radi ator drai n cock and radi ator
cap to drai n the cool ant. DO NOT waste usabl e cool -
ant. I f the sol uti on i s cl ean, drai n the cool ant i nto a
cl ean contai ner for reuse.
(4) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 28).
(5) Remove the l ower radi ator hose.
(6) Remove upper radi ator support retai ni ng bol ts
and remove radi ator support.
(7) Remove the fan assembl y from the water
pump.
(8) Remove the fan shroud (Fi g. 28).
(9) Di sconnect the transmi ssi on fl ui d cool er tubi ng
(automati c transmi ssi on).
(10) Vehicles with Air Conditioning:
(a) Di scharge the A/C system (refer to Group 24,
Heati ng and Ai r Condi ti oni ng).
(b) Remove the servi ce val ves and cap the com-
pressor ports.
(11) Remove the radi ator or radi ator/condenser (i f
equi pped wi th A/C).
(12) Di sconnect the heater hoses at the engi ne
thermostat housi ng and water pump (Fi g. 28).
(13) Di sconnect the throttl e l i nkages (Fi g. 29).
(14) Di sconnect the vehi cl e speed control cabl e (i f
equi pped) (Fi g. 29).
(15) Di sconnect the l i ne pressure cabl e (i f equi pped
wi th automati c transmi ssi on).
Fig. 27 Rear Engine Mount(4x4)
TRANS. ASSY.
BRACKET
CROSSMEMBER
Fig. 28 Upper Radiator Hose, Coolant
RecoveryHose, Fan Shroud & Heater hose
UPPER RADI- ATOR HOSE
HEATER
HOSES
FAN SHROUD COOLANT RECOV- ERY HOSE
9 - 28 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(16) Di sconnect i njecti on system wi re harness con-
nector at each i njector. Mark the wi res for proper
i nstal l ati on.
(17) Di sconnect the di stri butor el ectri cal connec-
ti on and the oi l pressure swi tch connector.
(18) Di sconnect the qui ck-connect fuel l i nes at the
fuel rai l and return l i ne by squeezi ng the two retai n-
i ng tabs agai nst the fuel tube (Fi g. 29). Pul l the fuel
tube and retai ner from the qui ck-connect fi tti ng
(refer to Group 14, Fuel System for the proper proce-
dure).
(19) Remove the fuel l i ne bracket from the i ntake
mani fol d.
(20) Remove the ai r cl eaner assembl y (Fi g. 30).
(21) Remove the power brake vacuum check val ve
from the booster, i f equi pped.
(22) Vehicles with Power Steering (Fig. 30):
(a) Di sconnect the hoses from the fi tti ngs at the
steeri ng gear.
(b) Drai n the pump reservoi r.
(c) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn objects from enteri ng the
system.
(23) I denti fy, tag and di sconnect al l necessary wi re
connectors and vacuum hoses.
(24) Rai se and support the vehi cl e.
(25) Di sconnect the wi res from the engi ne starter
motor sol enoi d.
(26) Remove the engi ne starter motor.
(27) Di sconnect the oxygen sensor from the
exhaust pi pe.
(28) Di sconnect the exhaust pi pe from the mani -
fol d.
(29) Di sconnect the vehi cl e speed sensor wi re con-
necti on.
(30) Remove the exhaust pi pe support.
(31) Remove the engi ne fl ywheel /converter housi ng
access cover.
(32) Vehicles with Automatic Transmission:
(a) Mark the converter and dri ve pl ate l ocati on.
(b) Remove the converter-to-dri ve pl ate bol ts.
(33) Remove the upper engi ne fl ywheel /converter
housi ng bol ts and l oosen the bottom bol ts.
(34) Remove the engi ne mount cushi on-to-engi ne
compartment bracket bol ts.
(35) Lower the vehi cl e.
(36) Attach a l i fti ng devi ce to the engi ne.
(37) Rai se the engi ne off the front supports.
(38) Pl ace a support or fl oor jack under the con-
verter (or engi ne fl ywheel ) housi ng.
(39) Remove the remai ni ng converter (or engi ne
fl ywheel ) housi ng bol ts.
(40) Li ft the engi ne out of the engi ne compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehi-
cle equipped with an automatic transmission, be
careful not to damage the trigger wheel on the
engine flywheel.
(1) Attach a l i fti ng devi ce to the engi ne and l ower
the engi ne i nto the engi ne compartment. For easi er
Fig. 29 Accelerator Cable, Vehicle SpeedControl
Cable, Automatic Transmission Control Cable &
Quick-Connect Fuel Lines
ACCELERATOR CABLE SPEED CONTROL CABLE QUICK-CONNECT FUEL LINES AUTOMATIC TRANS- MISSION CONTROL CABLE
Fig. 30 Air Cleaner Assembly & PowerSteering
Pump
POWER STEERING PUMP AIR CLEANER ASSEMBLY
ZG 4. 0L ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)
i nstal l ati on, i t may be necessary to remove the
engi ne mount bracket as an ai d i n al i gnment of the
engi ne to the transmi ssi on.
(2) Vehicles with Manual Transmission:
(a) I nsert the transmi ssi on shaft i nto the cl utch
spl i ne.
(b) Al i gn the engi ne fl ywheel housi ng wi th the
engi ne.
(c) I nstal l and ti ghten the engi ne fl ywheel hous-
i ng l ower bol ts fi nger ti ght.
(3) Vehicles with Automatic Transmission:
(a) Al i gn the transmi ssi on torque converter
housi ng wi th the engi ne.
(b) Loosel y i nstal l the converter housi ng l ower
bol ts and i nstal l the next hi gher bol t and nut on
each si de.
(c) Ti ghten al l 4 bol ts fi nger ti ght.
(4) I nstal l the engi ne mount brackets (i f removed).
(5) Lower the engi ne and engi ne mount brackets
onto the engi ne compartment cushi ons. I nstal l the
bol ts and fi nger ti ghten the nuts.
(6) Remove the engi ne l i fti ng devi ce.
(7) Rai se and support the vehi cl e.
(8) I nstal l the remai ni ng engi ne fl ywheel /converter
housi ng bol ts. Ti ghten al l bol ts to 38 Nm (28 ft. l bs.)
torque.
(9) Vehicles with Automatic Transmission:
(a) I nstal l the converter-to-dri ve pl ate bol ts.
(b) Ensure the i nstal l ati on reference marks are
al i gned.
(10) I nstal l the engi ne fl ywheel /converter housi ng
access cover.
(11) I nstal l the exhaust pi pe support and ti ghten
the screw.
(12) Ti ghten the engi ne mount-to-bracket bol ts.
(13) Connect the vehi cl e speed sensor wi re connec-
ti ons and ti ghten the screws.
(14) Connect the exhaust pi pe to the mani fol d.
(15) I nstal l the engi ne starter motor and connect
the cabl e.
(16) Connect the wi res to the engi ne starter motor
sol enoi d.
(17) Lower the vehi cl e.
(18) Connect al l the vacuum hoses and wi re con-
nectors i denti fi ed duri ng engi ne removal .
(19) Vehicles equipped with Power Steering:
(a) Remove the protecti ve caps
(b) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 Nm (38 ft. l bs.)
torque.
(c) Fi l l the pump reservoi r wi th fl ui d.
(20) I nstal l the power brake vacuum check val ve
from the booster, i f equi pped.
(21) Connect the fuel i nl et and return hoses at the
fuel rai l . Veri fy that the qui ck-connect fi tti ng assem-
bl y fi ts securel y over the fuel l i nes by gi vi ng the fuel
l i nes a fi rm tug.
(22) I nstal l the fuel l i ne bracket to the i ntake
mani fol d.
(23) Connect the di stri butor el ectri cal connector
and oi l pressure swi tch connector.
(24) Connect the i njecti on system wi res to the
i njectors.
(25) Connect the l i ne pressure cabl e (i f equi pped
wi th automati c transmi ssi on).
(26) Connect the vehi cl e speed control cabl e, i f
equi pped.
(27) Connect the throttl e cabl e l i nkages.
(28) Connect the heater hoses at the engi ne ther-
mostat housi ng and water pump.
(29) I nstal l the fan assembl y to the water pump.
(30) Pl ace the fan shroud i n posi ti on over the fan.
(31) I nstal l the radi ator or radi ator/condenser (i f
equi pped wi th A/C).
(32) Connect the servi ce val ves to the A/C com-
pressor ports, i f equi pped wi th A/C.
(33) Charge the ai r condi ti oner system (refer to
Group 24, Heati ng and Ai r Condi ti oni ng).
(34) Connect the radi ator hoses and automati c
transmi ssi on fl ui d cool er pi pes, i f equi pped.
(35) I nstal l the fan shroud to the radi ator or radi -
ator/condenser (i f equi pped wi th A/C).
(36) I nstal l upper radi ator support.
(37) Connect the upper radi ator hose and ti ghten
the cl amp.
(38) Connect the l ower radi ator hose and ti ghten
the cl amp.
(39) Fi l l the cool i ng system wi th reusabl e cool ant
or new cool ant (refer to Group 7, Cool i ng System).
(40) Al i gn the hood to the scri be marks. I nstal l the
hood.
(41) Connect the vacuum harness connector.
(a) Fi rml y push the connectors together ensur-
i ng that the retai ni ng tabs are engaged.
(b) I nsert the vacuum connector assembl y i nto
the retai ni ng bracket on the i ntake mani fol d.
(42) I nstal l the ai r cl eaner assembl y.
(43) I nstal l the battery and connect the battery
cabl e.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(44) Start the engi ne, i nspect for l eaks and correct
the fl ui d l evel s, as necessary.
ENGINE CYLINDER HEAD COVER
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
9 - 30 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
There are two cyl i nder head bol ts that have a pi n
to l ocate the cyl i nder head cover gasket, they are
l ocated at posi ti on 8 and 9 (Fi g. 32)
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover.
(3) Di sconnect the fresh ai r i nl et hose from the
engi ne cyl i nder head cover.
(4) Di sconnect the accel erator, transmi ssi on, and
speed (i f equi pped) control cabl es from the throttl e
body (Fi g. 31).
(5) Remove the three bol ts that fasten the control
cabl e bracket to the i ntake mani fol d.
(6) Remove control cabl es from cyl i nder head cover
cl i p.
(7) Posi ti on control cabl es and bracket away from
cyl i nder head cover secure wi th ti e straps.
(8) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(9) Remove the engi ne cyl i nder head cover and
gasket.
INSTALLATION
(1) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet and oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(2) I nstal l cyl i nder head cover and gasket. Ti ghten
the mounti ng bol ts to 8.5 Nm (75 i n. l bs.) torque.
(3) Connect the CCV hoses.
(4) I nstal l control cabl es and bracket on i ntake
mani fol d and ti ghten bol ts to 8.7 Nm (77 i n. l bs.)
torque.
(5) Connect control cabl es to throttl e body l i nkage.
(6) Snap control cabl es i nto cyl i nder head cover
cl i p.
(7) Connect negati ve cabl e to battery.
ROCKER ARMS AND PUSH RODS
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
(1) Remove the engi ne cyl i nder head cover.
(2) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 33). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(3) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 33). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
Fig. 31 Engine Cylinder Head Cover
TRANS CONTROL CABLE
ACCELERATOR CABLE
CONTROL CABLE BRACKET
Fig. 32 Cylinder Head Cover GasketLocator Pins at
#8 & #9
FRONT
Fig. 33 Rocker Arm Assembly
CAPSCREWS BRIDGE PIVOT ASSEMBLY PUSH RODS ROCKER ARMS
ZG 4. 0L ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or equi v-
al ent, l ubri cate the area of the rocker arm that the
pi vot contacts. I nstal l rocker arms, pi vots and bri dge
above each cyl i nder i n thei r ori gi nal l y posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 Nm (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover.
VALVE STEM SEAL AND SPRING
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(1) Remove the engi ne cyl i nder head cover.
(2) Remove capscrews, bri dge and pi vot assembl i es
and rocker arms for access to each val ve spri ng to be
removed.
(3) Remove push rods. Retai n the push rods,
bri dges, pi vots and rocker arms i n the same order
and posi ti on as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 34).
(8) Remove val ve spri ng and retai ner (Fi g. 34).
(9) Remove val ve stem oi l seal s (Fi g. 34). Note the
val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(I ntake) or EXH (Exhaust). DO NOT mi x the seal s.
INSTALLATION
CAUTION: Install oil seals carefully to prevent
damage from the sharp edges of the valve spring
lock grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Di sconnect the ai r hose. Remove the adaptor
from the spark pl ug hol e and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge capscrews al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
(9) I nstal l the engi ne cyl i nder head cover.
ENGINE CYLINDER HEAD
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
Fig. 34 Valve and Valve Components
RETAINER VALVE STEM OIL SEAL INTAKEVALVE EXHAUST VALVE VALVE SPRING VALVELOCKS
9 - 32 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant and di sconnect the hoses at
the engi ne thermostat housi ng. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean and i s bei ng
drai ned onl y to servi ce the engi ne or cool i ng system,
drai n the cool ant i nto a cl ean contai ner for reuse.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the engi ne cyl i nder head cover.
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms.
(6) Remove the push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order as removed.
(7) Loosen the serpenti ne dri ve bel t at the power
steeri ng pump, i f equi pped or at the i dl er pul l ey
(refer to Group 7, Cool i ng System for the proper pro-
cedure).
(8) I f equi pped wi th ai r condi ti oni ng, remove the
ai r condi ti oni ng compressor, (refer to Group 24, Heat-
i ng and Ai r Condi ti oni ng).
(9) I f equi pped, di sconnect the power steeri ng
pump bracket. Set the pump and bracket asi de. DO
NOT di sconnect the hoses.
(10) Perform the Fuel System Pressure Rel ease
procedure (refer to Group 14, Fuel System).
(11) Remove the fuel l i nes.
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head (refer to Group
11, Exhaust System and I ntake Mani fol d for the
proper procedures).
(13) Di sconnect the i gni ti on wi res and remove the
spark pl ugs.
(14) Di sconnect the temperature sendi ng uni t wi re
connector.
(15) Remove the i gni ti on coi l and bracket assem-
bl y.
(16) Remove the engi ne cyl i nder head bol ts. Bol t
No.14 cannot be removed unti l the head i s moved for-
ward (Fi g. 35). Pul l bol t No.14 out as far as i t wi l l go
and then suspend the bol t i n thi s posi ti on (tape
around the bol t).
(17) Remove the engi ne cyl i nder head and gasket
(Fi g. 35).
(18) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i snt known i f they were used before, di scard the
bol ts.
(19) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) Posi ti on the engi ne cyl i nder head gasket (wi th
the numbers faci ng up) usi ng the al i gnment dowel s
i n the cyl i nder bl ock, to posi ti on the gasket.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(3) Wi th bol t No.14 hel d i n pl ace (tape around
bol t), i nstal l the engi ne cyl i nder head over the same
dowel s used to l ocate the gasket. Remove the tape
from bol t No.14.
(4) Coat the threads of stud bol t No.11 wi th Loc-
ti te 592 seal ant, or equi val ent.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
36).
CAUTION: During the final tightening sequence,
bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.
Fig. 35 Engine Cylinder Head Assembly
CYLINDER HEAD BOLTS
CYLINDER HEAD GASKET
CYLINDER HEAD
ZG 4. 0L ENGINE 9 - 33
REMOVAL AND INSTALLATION (Continued)
(a) Ti ghten al l bol ts i n sequence (1 through 14)
to 30 Nm (22 ft. l bs.) torque.
(b) Ti ghten al l bol ts i n sequence (1 through 14)
to 61 Nm (45 ft. l bs.) torque.
(c) Check al l bol ts to veri fy they are set to 61
Nm (45 ft. l bs.) torque.
(d) Ti ghten bol ts i n sequence:
Bol ts 1 through 10 to 149 Nm (110 ft. l bs.)
torque.
Bol t 11 to 13 Nm (100 ft. l bs.) torque.
Bol ts 12 through 14 to 149 Nm (110 ft. l bs.)
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(6) I nstal l the i gni ti on coi l and bracket assembl y.
(7) Connect the temperature sendi ng uni t wi re
connector.
(8) I nstal l the spark pl ugs and ti ghten to 37 Nm
(27 ft. l bs.) torque. Connect the i gni ti on wi res.
(9) I nstal l the i ntake and engi ne exhaust mani -
fol ds (refer to Group 11, Exhaust System and I ntake
Mani fol d for the proper procedures).
(10) I nstal l the fuel l i nes and the vacuum advance
hose.
(11) I f equi pped, attach the power steeri ng pump
and bracket.
(12) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed (refer to
Rocker Arms and Push Rods i n thi s secti on).
(13) I nstal l the engi ne cyl i nder head cover.
(14) Attach the ai r condi ti oner compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
Ti ghten the bol ts to 40 Nm (30 ft. l bs.) torque.
(15) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.)
torque.
CAUTION: The serpentine drive belt must be
routed correctly. Incorrect routing can cause the
water pump to turn in the opposite direction caus-
ing the engine to overheat.
(16) I nstal l the serpenti ne dri ve bel t and correctl y
tensi on the bel t (refer to Group 7, Cool i ng System for
the proper procedure).
(17) I nstal l the ai r cl eaner and ducti ng.
(18) I nstal l the engi ne cyl i nder head cover.
(19) Connect the hoses to the engi ne thermostat
housi ng and fi l l the cool i ng system to the speci fi ed
l evel (refer to Group 7, Cool i ng Systems for the
proper procedure).
(20) The automati c transmi ssi on throttl e l i nkage
and cabl e must be adjusted after compl eti ng the
engi ne cyl i nder head i nstal l ati on (refer to Group 21,
Transmi ssi ons for the proper procedures).
(21) I nstal l the temperature sendi ng uni t and con-
nect the wi re connector.
(22) Connect the fuel l i ne.
(23) I f equi pped wi th ai r condi ti oni ng, i nstal l ai r
compressor and charge A/C system (refer to Group 24
Heati ng and Ai r Condi ti oni ng).
(24) Connect negati ve cabl e to battery.
(25) Connect the upper radi ator hose and heater
hose at the engi ne thermostat housi ng.
(26) Fi l l the cool i ng system. Check for l eaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(27) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the engi ne thermostat opens. Add cool ant, i f
requi red.
VALVES AND VALVE SPRINGS
Thi s procedure i s done wi th the engi ne cyl i nder
head removed from the bl ock.
CYLINDER HEAD BOLTS
POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
8,9 1/2 in.-13 BOLT WITH
DOWEL POINT
2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16
in.-14 STUD END
All bolts are 12 point drives for rocker cover
clearance
Fig. 36 Engine Cylinder Head Bolt
TighteningSequence
FRONT
9 - 34 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Remove the engi ne cyl i nder head from the cyl -
i nder bl ock.
(2) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s.
(4) Use a smooth stone or a jewel ers fi l e to remove
any burrs on the top of the val ve stem, especi al l y
around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
the same order as removed.
INSTALLATION
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems. I f the 0.381 mm (0.015 i nch) over-
si ze val ve stems are used, oversi ze oi l seal s are
requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
(8) I nstal l the engi ne cyl i nder head.
HYDRAULIC TAPPETS
Retai n al l the components i n the same order as
removed.
REMOVAL
(1) Remove the engi ne cyl i nder head (Refer to cyl -
i nder head r&i i n thi s secti on).
(2) Remove the push rods.
(3) Remove the tappets through the push rod open-
i ngs i n the cyl i nder bl ock wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 37).
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the cyl i nder head assy (Refer to cyl i nder
head r&i i n thi s secti on).
(4) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(5) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(6) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
(7) Pour the remai ni ng Mopar Engi ne Oi l Suppl e-
ment, or equi val ent over the enti re val ve actuati ng
assembl y. The Mopar Engi ne Oi l Suppl ement, or
equi val ent must remai n wi th the engi ne oi l for at
l east 1 609 km (1,000 mi l es). The oi l suppl ement
need not be drai ned unti l the next schedul ed oi l
change.
(8) I nstal l the engi ne cyl i nder head cover.
VIBRATION DAMPER
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the serpenti ne dri ve bel t and fan
shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 38).
INSTALLATION
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n posi ti on, al i gn the keyway on the
vi brati on damper hub wi th the crankshaft key and
tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 Nm
(80 ft. l bs.) torque.
(4) I nstal l the serpenti ne dri ve bel t and ti ghten to
the speci fi ed tensi on (refer to Group 7, Cool i ng Sys-
tems for the proper speci fi cati ons and procedures).
(5) Connect negati ve cabl e to battery.
Fig. 37 Hydraulic Valve Tappet Removal
InstallationTool
HYDRAULIC TAPPET REMOVAL TOOL
CYLINDER BLOCK
ZG 4. 0L ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)
TIMING CASE COVER
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the vi brati on damper.
(3) Remove the fan and hub assembl y and remove
the fan shroud.
(4) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(5) Remove the A/C compressor (i f equi pped) and
generator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(7) Remove the ti mi ng case cover and gasket from
the engi ne. Make sure the tensi on spri ng and thrust
pi n do not fal l out of the prel oad bol t.
(8) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 39).
INSTALLATION
Cl ean the ti mi ng case cover, oi l pan and cyl i nder
bl ock gasket surfaces.
(1) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(2) Posi ti on the gasket on the cyl i nder bl ock.
(3) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock. Make sure the tensi on
spri ng and thrust pi n are i n pl ace i n the camshaft
prel oad bol t.
(4) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 40).
(5) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
(6) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
Nm (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 Nm (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 9.5 Nm
(84 i n. l bs.) torque. Ti ghten the oi l pan-to-cover 5/16
i nch bol ts to 15 Nm (132 i n. l bs.) torque.
(7) Remove the cover al i gnment tool .
(8) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
(9) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(10) I nstal l the A/C compressor (i f equi pped) and
generator bracket assembl y.
(11) I nstal l the engi ne fan and hub assembl y and
shroud.
Fig. 38 Vibration Damper Removal Tool 7697
VIBRATION DAMPER REMOVAL TOOL WRENCH
Fig. 39 Timing Case Cover Components
VIBRATION DAMPER PULLEY TIMING CASE COVER OIL SLINGER CRANKSHAFT OIL SEAL
Fig. 40 Timing Case Cover Alignment and
SealInstallation Tool 6139
TIMING CASE COVER ALIGN- MENT AND SEAL INSTALLA- TION TOOL
9 - 36 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(12) I nstal l the serpenti ne dri ve bel t and ti ghten
to obtai n the speci fi ed tensi on.
(13) Connect negati ve cabl e to battery.
TIMING CHAIN AND SPROCKETS
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the fan and shroud.
(3) Remove the serpenti ne dri ve bel t.
(4) Remove the crankshaft vi brati on damper.
(5) Remove the ti mi ng case cover.
(6) Rotate crankshaft unti l the 0 ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 41).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the tensi on spri ng and thrust pi n from
the prel oad bol t (Fi g. 42). Remove the camshaft
sprocket retai ni ng prel oad bol t and washer.
(9) Remove the crankshaft sprocket, camshaft
sprocket and ti mi ng chai n as an assembl y.
(10) I nstal l ati on of the ti mi ng chai n wi th the ti m-
i ng marks on the crankshaft and camshaft sprockets
properl y al i gned ensures correct val ve ti mi ng. A worn
or stretched ti mi ng chai n wi l l adversel y affect val ve
ti mi ng. I f the ti mi ng chai n defl ects more than 12.7
mm (1/2 i nch) repl ace i t. The correct ti mi ng chai n
has 48 pi ns. A chai n wi th more than 48 pi ns wi l l
cause excessi ve sl ack.
INSTALLATION
Assembl e the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned (Fi g. 43).
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n the keyway on the crankshaft, i nstal l
the assembl y on the crankshaft and camshaft.
(2) I nstal l the camshaft sprocket retai ni ng prel oad
bol t and washer (Fi g. 42). Ti ghten the prel oad bol t to
108 Nm (80 ft. l bs.) torque.
(3) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft to posi ti on the camshaft
sprocket ti mi ng mark as shown i n (Fi g. 43). Count
the number of chai n pi ns between the ti mi ng marks
of both sprockets. There must be 15 pi ns.
(4) I nstal l the crankshaft oi l sl i nger.
(5) Repl ace the oi l seal i n the ti mi ng case cover.
(6) Lubri cate the tensi on spri ng, thrust pi n and
pi n bore i n the prel oad bol t wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent. I nstal l the spri ng and
thrust pi n i n the prel oad bol t head (Fi g. 42).
(7) I nstal l the ti mi ng case cover and gasket.
Fig. 41 CrankshaftCamshaft AlignmentTypical
TIMING MARKS CRANKSHAFT SPROCKET CAMSHAFT SPROCKET
Fig. 42 Camshaft Sprocket Preload Bolt
CAMSHAFT SPROCKET WASHER TENSION SPRING THRUST PIN PRELOAD BOLT
Fig. 43 Verify SprocketChain InstallationTypical
CAMSHAFT SPROCKET 15 PINS CRANKSHAFT SPROCKET TIMING MARKS
ZG 4. 0L ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)
(8) Wi th the key i nstal l ed i n the crankshaft key-
way, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(9) I nstal l the serpenti ne dri ve bel t and ti ghten to
the speci fi ed tensi on (refer to Group 7, Cool i ng Sys-
tem for the proper procedure).
(10) I nstal l the fan and hub assembl y. I nstal l the
shroud.
(11) Connect negati ve cabl e to battery.
CAMSHAFT
REMOVAL
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n the cool i ng system. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto a
cl ean contai ner for reuse.
(3) Remove the radi ator or radi ator and condenser,
i f equi pped wi th A/C (refer to Group 7, Cool i ng Sys-
tem for the proper procedure).
(4) Remove the ai r condi ti oner condenser and
recei ver/dri er assembl y as a charged uni t, i f equi pped
(refer to Group 24, Heati ng and Ai r Condi ti oni ng).
(5) Remove the di stri butor cap and mark the posi -
ti on of the rotor.
(6) Remove the di stri butor and i gni ti on wi res.
(7) Remove the engi ne cyl i nder head cover.
(8) Remove the rocker arms, bri dges and pi vots.
(9) Remove the push rods.
(10) Remove the engi ne cyl i nder head and gasket.
(11) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder bl ock.
(12) Remove the vi brati on damper.
(13) Remove the ti mi ng case cover.
(14) Remove the ti mi ng chai n and sprockets.
(15) Remove the front bumper and/or gri l l e, as
requi red.
(16) Remove the camshaft (Fi g. 44).
INSTALLATION
(1) I nspect the cam l obes for wear.
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the ti mi ng case cover, exami ne the oi l pres-
sure rel i ef hol es i n the rear cam journal . The oi l
pressure rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent.
(7) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs (Fi g. 44).
(8) I nstal l the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned.
(9) I nstal l the camshaft sprocket retai ni ng prel oad
bol t. Ti ghten the bol t to 108 Nm (80 ft. l bs.) torque.
(10) Lubri cate the tensi on spri ng, the thrust pi n
and the pi n bore i n the prel oad bol t wi th Mopar
Engi ne Oi l Suppl ement, or equi val ent. I nstal l the
spri ng and thrust pi n i n the prel oad bol t head.
(11) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 45). Refer to Ti mi ng Case Cover
I nstal l ati on.
(12) I nstal l the vi brati on damper (Fi g. 45).
(13) I nstal l the hydraul i c val ve tappets.
(14) I nstal l the cyl i nder head gasket wi th the
numbers faci ng up.
Fig. 44 Camshaft
CAMSHAFT CRANKSHAFT
Fig. 45 Timing Case Cover Components
VIBRATION DAMPER PULLEY TIMING CASE COVER OIL SLINGER CRANKSHAFT OIL SEAL
9 - 38 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(15) I nstal l the cyl i nder head and head bol ts
(Refer to cyl i nder head R&I i n thi s secti on for torque
val ues and ti ghteni ng sequence).
(16) I nstal l the push rods.
(17) I nstal l the rocker arms and pi vot and bri dge
assembl i es. Ti ghten each of the capscrews for each
bri dge al ternatel y, one turn at a ti me, to avoi d dam-
agi ng the bri dge (Refer to Rocker Arms and Push
Rods i n thi s secti on).
(18) I nstal l the engi ne cyl i nder head cover.
(19) Posi ti on the oi l pump gear. Refer to Di stri bu-
tor i n the Component Removal /I nstal l ati on secti on of
Group 8D, I gni ti on Systems.
(20) I nstal l the di stri butor and i gni ti on wi res.
Refer to Di stri butor i n the Component Removal /I n-
stal l ati on secti on of Group 8D, I gni ti on Systems.
(21) I nstal l the serpenti ne dri ve bel t and ti ghten
to the speci fi ed tensi on (refer to Group 7, Cool i ng
System for the proper procedure).
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with Mopar
Engine Oil Supplement, or equivalent. The Mopar
Engine Oil Supplement, or equivalent must remain
with the engine oil for at least 1609 km (1,000
miles). The oil supplement need not be drained until
the next scheduled oil change.
(22) I nstal l the A/C condenser and recei ver/dri er
assembl y, i f equi pped (refer to Group 24, Heati ng and
Ai r Condi ti oni ng).
CAUTION: Both service valves must be opened
before the air conditioning system is operated.
(23) I nstal l the radi ator, connect the hoses and fi l l
the cool i ng system to the speci fi ed l evel (refer to
Group 7, Cool i ng System for the proper procedure).
(24) Check the i gni ti on ti mi ng and adjust as nec-
essary.
(25) I nstal l the gri l l e and bumper, i f removed.
(26) Connect negati ve cabl e to battery.
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n the radi ator. DO NOT waste reusabl e
cool ant. Drai n the cool ant i nto a cl ean contai ner.
(3) Remove the fan and shroud.
(4) Di sconnect the radi ator overfl ow tube, radi ator
hoses, automati c transmi ssi on fl ui d cool er pi pes (i f
equi pped).
(5) Remove the radi ator.
(6) I f equi pped wi th ai r condi ti oni ng:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
(a) Remove the A/C compressor serpenti ne dri ve
bel t i dl er pul l ey.
(b) Di sconnect and remove the generator.
(c) Remove the A/C condenser attachi ng bol ts
and move the condenser and recei ver/dri er assem-
bl y up and out of the way.
(7) Remove the serpenti ne dri ve bel t.
(8) Remove the crankshaft vi brati on damper.
(9) Remove the ti mi ng case cover. Cl ean the gasket
materi al from the cover.
(10) Remove the thrust pi n and tensi on spri ng
from the prel oad bol t head.
(11) Rotate crankshaft unti l the crankshaft
sprocket ti mi ng mark i s cl osest to and on the center
l i ne wi th the camshaft sprocket ti mi ng mark (Fi g.
46).
(12) Remove the camshaft sprocket prel oad retai n-
i ng bol t and washer.
(13) Remove the crankshaft oi l sl i nger.
(14) Remove the sprockets and chai n as an assem-
bl y.
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(15) I nspect the damaged camshaft pi n.
(16) I f the pi n i s a spri ng-type pi n, remove the bro-
ken pi n by i nserti ng a sel f-tappi ng screw i nto the pi n
and careful l y pul l i ng the pi n from the camshaft.
Fig. 46 Timing Chain AlignmentTypical
TIMING MARKS CRANKSHAFT SPROCKET CAMSHAFT SPROCKET
ZG 4. 0L ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)
(17) I f the pi n i s a dowel -type pi n, center-punch i t.
Ensure the exact center i s l ocated when center-
punchi ng the pi n.
CAUTION: Cover the opened oil pan area to pre-
vent metal chips from entering the pan.
(18) Dri l l i nto the pi n center wi th a 4 mm (5/32
i nch) dri l l bi t.
(19) I nsert a sel f-tappi ng screw i nto the dri l l ed pi n
and careful l y pul l the pi n from the camshaft.
CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated.
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available.
Camshaft end pl ay i s mai ntai ned by the l oad
pl aced on the camshaft by the sprocket prel oad bol t
tensi on spri ng and thrust pi n.
INSTALLATION
(1) Cl ean the camshaft pi n hol e.
(2) Compress the center of the repl acement spri ng
pi n wi th vi se gri ps.
(3) Careful l y dri ve the pi n i nto the camshaft pi n
hol e unti l i t i s seated.
(4) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n wi th the ti mi ng marks
al i gned (Fi g. 46).
(5) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft to posi ti on the camshaft
sprocket ti mi ng mark as shown i n (Fi g. 47). Count
the number of chai n pi ns between the ti mi ng marks
of both sprockets. There must be 15 pi ns.
(6) I nstal l the crankshaft oi l sl i nger.
(7) Ti ghten the camshaft sprocket prel oad bol t to
108 Nm (80 ft. l bs.) torque.
(8) Check the val ve ti mi ng.
(9) Lubri cate the tensi on spri ng, the thrust pi n
and the pi n bore i n the prel oad bol t wi th Mopar
Engi ne Oi l Suppl ement, or equi val ent. I nstal l the
spri ng and thrust pi n i n the prel oad bol t head.
(10) Coat both si des of the repl acement ti mi ng
case cover gasket wi th gasket seal er. Appl y a 3 mm
(1/8 i nch) bead of Mopar Si l i cone Rubber Adhesi ve
Seal ant, or equi val ent to the joi nt formed at the oi l
pan and cyl i nder bl ock.
(11) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(12) Pl ace Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 48).
(13) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
bol ts. I nstal l the oi l pan-to-ti mi ng case cover bol ts.
(14) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
Nm (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 Nm (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 14 Nm
Fig. 47 Verify CrankshaftCamshaftInstallation
Typical
CAMSHAFT SPROCKET 15 PINS CRANKSHAFT SPROCKET TIMING MARKS
Fig. 48 Timing Case Cover Alignment and
SealInstallation Tool 6139
TIMING CASE COVER ALIGN- MENT AND SEAL INSTALLA- TION TOOL
9 - 40 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(120 i n. l bs.) torque. Ti ghten the oi l pan-to-cover 5/16
i nch bol ts to 18 Nm (156 i n. l bs.) torque.
(15) Remove the cover al i gnment tool and i nstal l a
repl acement oi l seal i nto the cover.
(16) I nstal l the vi brati on damper on the crank-
shaft.
(17) Lubri cate and ti ghten the damper bol t to 108
Nm (80 ft. l bs.) torque.
(18) I f equi pped wi th ai r condi ti oni ng:
(a) I nstal l the A/C compressor serpenti ne dri ve
bel t i dl er pul l ey.
(b) I nstal l the generator.
(c) I nstal l the A/C condenser and recei ver/dri er
assembl y.
(19) I nstal l the serpenti ne dri ve bel t on the pul l eys
and ti ghten (refer to Group 7, Cool i ng System for the
speci fi cati ons and procedures).
(20) I nstal l the radi ator. Connect the radi ator
hoses and automati c transmi ssi on fl ui d cool er pi pes,
i f equi pped. Fi l l the cool i ng system.
(21) I nstal l the fan and shroud.
(22) Connect negati ve cabl e to battery.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the spark pl ugs.
(3) Rai se the vehi cl e.
(4) Remove the oi l pan and oi l pump.
(5) Remove mai n beari ng cap brace (Fi g. 49).
(6) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 50).
(7) Remove the l ower i nsert from the beari ng cap.
(8) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 51). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 51). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(9) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(5) Ti ghten the bol ts of caps 1, 2, 4, 5, 6, and 7 to
54 Nm (40 ft. l bs.) torque. Now ti ghten these bol ts to
95 Nm (70 ft. l bs.) torque. Fi nal l y, ti ghten these
bol ts to 108 Nm (80 ft. l bs.) torque.
(6) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.3 to 54 Nm (40 ft. l bs.) torque. Then ti ghten
to 95 Nm (70 ft. l bs.) torque and fi nal l y ti ghten to
108 Nm (80 ft. l bs.) torque.
Fig. 49 Main Bearing Caps and Brace.
BLOCK
MAIN BEARING CAP BRACE
Fig. 50 Removing Main Bearing Caps and
LowerInserts
CONNECTING ROD JOUR- NAL
MAIN BEARING CAPS
ZG 4. 0L ENGINE 9 - 41
REMOVAL AND INSTALLATION (Continued)
(7) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(8) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 52). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(9) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock (refer to Cyl i nder
Bl ock - Assembl e).
(10) I nstal l mai n beari ng cap brace ti ghten nuts to
47 Nm (35 ft. l bs.) torque.
(11) I nstal l oi l pump assy. and ti ghten attachi ng
bol ts to 23 Nm (17 ft. l bs.)
(12) I nstal l the oi l pan.
(13) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
Nm (25 ft. l bs.) torque.
(14) Lower the vehi cl e.
(15) I nstal l the spark pl ugs. Ti ghten the pl ugs to
37 Nm (27 ft. l bs.) torque.
(16) Fi l l the oi l pan wi th engi ne oi l to the ful l
mark on the di psti ck l evel .
(17) Connect negati ve cabl e to battery.
OIL PAN
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the exhaust
mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(6) Remove the starter motor.
(7) Remove the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(8) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(9) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(10) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(11) Remove the engi ne mount through bol ts.
(12) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(13) Remove the oi l pan bol ts. Careful l y sl i de the
oi l pan and gasket to the rear. I f equi pped wi th an oi l
l evel sensor, take care not to damage the sensor.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
Fig. 51 Removing Upper Inserts
COTTER PIN
FABRICATING TOOL
BEARING INSERT
Fig. 52 Crankshaft End Play Measurement
DIAL INDICATOR CRANKSHAFT
9 - 42 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(2) Fabri cate 4 al i gnment dowel s from 1 1/2 x 1/4
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 53).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 54).
(4) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(5) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(6) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 Nm (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 55). Ti ghten these bol ts to 15
Nm (132 i n. l bs.) torque.
(7) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 Nm (84
i n. l bs.) torque.
(8) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(9) I nstal l the through bol ts and ti ghten the nuts.
(10) Lower the jack stand and remove the pi ece of
wood.
(11) I nstal l the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(12) I nstal l the engi ne starter motor.
(13) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(14) I nstal l the oi l pan drai n pl ug (Fi g. 55).
Ti ghten the pl ug to 34 Nm (25 ft. l bs.) torque.
(15) Lower the vehi cl e.
(16) Connect negati ve cabl e to battery.
(17) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(18) Start the engi ne and i nspect for l eaks.
PISTONS AND CONNECTING RODS
REMOVAL
(1) Remove the engi ne cyl i nder head cover.
(2) Remove the rocker arms, bri dges and pi vots.
(3) Remove the push rods.
(4) Remove the engi ne cyl i nder head.
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(6) Rai se the vehi cl e.
(7) Drai n the engi ne oi l .
(8) Remove the oi l pan and gasket.
(9) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 56).
(10) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
Fig. 53 Fabrication of Alignment Dowels
1/4 1 1/2 BOLT DOWEL SLOT
Fig. 54 Position of Dowels in Cylinder Block
DOWEL HOLES CYLINDERBLOCK
5/16 HOLES 5/16
HOLES
Fig. 55 Position of 5/16 inch Oil Pan Bolts
5/16 BOLTSOIL PAN DRAIN PLUG OIL PAN
ZG 4. 0L ENGINE 9 - 43
REMOVAL AND INSTALLATION (Continued)
CAUTION: Ensure that the connecting rod bolts
DO NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(11) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 57).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed.
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 58).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 58).
(6) Rai se the vehi cl e.
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
Fig. 56 Stamped Connecting Rods and Caps
CONNECTING ROD CAP CONNECTING ROD
Fig. 57 Removal of Connecting Rod and
PistonAssembly
PISTON CONNECTING ROD BLOCK
Fig. 58 Rod and Piston Assembly Installation
9 - 44 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.
(11) I nstal l the oi l pan and gaskets as outl i ned i n
the i nstal l ati on procedure.
(12) Lower the vehi cl e.
(13) I nstal l the engi ne cyl i nder head, push rods,
rocker arms, bri dges, pi vots and engi ne cyl i nder head
cover.
(14) Fi l l the crankcase wi th engi ne oi l .
REAR MAIN OIL SEALS
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
REMOVAL
(1) Remove the transmi ssi on i nspecti on cover.
(2) Remove the oi l pan.
(3) Remove the rear mai n beari ng cap (No.7).
(4) Push the upper seal out of the groove. Ensure
that the crankshaft and seal groove are not damaged.
(5) Remove the l ower hal f of the seal from the
beari ng cap.
INSTALLATION
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Appl y a thi n coat of engi ne oi l .
(3) Coat the l i p of the seal wi th engi ne oi l .
(4) Careful l y posi ti on the upper seal i nto the
groove i n the cyl i nder bl ock. The l i p of the seal faces
toward the front of the engi ne.
(5) Pl ace the l ower hal f of the seal i nto beari ng cap
No.7 (Fi g. 59).
(6) Coat the outer curved surface of the l ower seal
wi th soap and the l i p of the seal wi th engi ne oi l (Fi g.
59).
(7) Posi ti on the l ower seal i nto the beari ng cap
recess and seat i t fi rml y. Be sure the seal i s fl ush
wi th the cyl i nder bl ock pan rai l .
(8) Appl y Locti te 518, or equi val ent on the rear
beari ng cap (Fi g. 60). The bead shoul d be 3 mm
(0.125 i n) thi ck. DO NOT appl y Locti te 518, or equi v-
al ent to the l i p of the seal .
(9) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(10) Ti ghten al l mai n beari ng bol ts to 108 Nm (80
ft. l bs.) torque.
(11) I nstal l the oi l pan gasket and oi l pan.
(12) I nstal l the engi ne fl ywheel or converter dri ve
pl ate.
OIL PUMP
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
Fig. 59 Rear Main Bearing Oil Seal
REAR MAIN BEARING SEAL BEARING CAP BEARING CAP
Fig. 60 Location of Loctite 518 (or equivalent)
LOCTITE 518 (OR EQUIVA- LENT) REAR MAIN BEAR- ING CAP
19 mm
(0.75 in)
6 mm (0.25 in)
ZG 4. 0L ENGINE 9 - 45
REMOVAL AND INSTALLATION (Continued)
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
REMOVAL
(1) Drai n the engi ne oi l .
(2) Remove the oi l pan.
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
61).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 Nm
(17 ft. l bs.) torque.
(2) I nstal l the oi l pan.
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
TIMING CASE COVER OIL SEAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the serpenti ne dri ve bel t.
(3) Remove the vi brati on damper.
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 62). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
(4) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(5) I nstal l the serpenti ne bel t and ti ghten to the
speci fi ed tensi on (refer to Group 7, Cool i ng Systems
for the proper speci fi cati ons and procedures).
(6) I nstal l the radi ator shroud.
(7) Connect negati ve cabl e to battery.
DISASSEMBLY AND ASSEMBLY
VALVE SERVICE
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Fig. 61 Oil Pump Assembly
OIL FILTER ADAPTOR BLOCK GASKET OIL INLET TUBE OIL PUMP STRAINER ASSEMBLY ATTACHING BOLTS
Fig. 62 Timing Case Cover Oil Seal Installation
SEAL INSTALLA- TION TOOL DRAW SCREW TOOL
9 - 46 4. 0L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 63). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 64).
VALVE STEM OIL SEAL REPLACEMENT
Val ve stem oi l seal s are i nstal l ed on each val ve
stem to prevent rocker arm l ubri cati ng oi l from
enteri ng the combusti on chamber through the val ve
gui de bores. One seal i s marked I NT (i ntake val ve)
and the other i s marked EXH (exhaust val ve).
Repl ace the oi l seal s whenever val ve servi ce i s per-
formed or i f the seal s have deteri orated.
VALVE GUIDES
The val ve gui des are an i ntegral part of the engi ne
cyl i nder head and are not repl aceabl e.
When the val ve stem gui de cl earance i s excessi ve,
the val ve gui de bores must be reamed oversi ze. Ser-
vi ce val ves wi th oversi ze stems are avai l abl e i n 0.076
mm (0.003 i nch) and 0.381 mm (0.015 i nch) i ncre-
ments.
Correspondi ng oversi ze val ve stem seal s are al so
avai l abl e and must be used wi th val ves havi ng 0.381
mm (0.015 i nch) oversi ze stems.
NOTE: If the valve guides are reamed oversize, the
valve seats must be ground to ensure that the valve
seat is concentric to the valve guide.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
Val ve stem-to-gui de cl earance may be measured by
ei ther of the fol l owi ng two methods.
PREFERRED METHOD
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 65).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
Fig. 63 Valve Facing Margin
VALVE MARGIN NO MARGIN INCORRECT VALVE FACING CORRECT VALVE FACING
Fig. 64 Measurement of Valve Seat Runout
DIAL INDI- CATOR
ZG 4. 0L ENGINE 9 - 47
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
ALTERNATIVE METHOD
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 66).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 67).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
CYLINDER BLOCK
DISASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) Drai n the engi ne oi l . Remove and di scard the
oi l fi l ter.
(2) Remove the water pump from the cyl i nder
bl ock.
(3) Remove the vi brati on damper.
(4) Remove the ti mi ng case cover and l ay the cover
upsi de down.
(5) Posi ti on a dri ft punch i nto the sl ot i n the back
of the cover and tap the ol d seal out.
(6) Remove the oi l sl i nger from crankshaft.
(7) Remove the camshaft retai ni ng bol t and
remove the sprockets and chai n as an assembl y.
(8) Remove the camshaft.
(9) Remove the oi l pan and gasket.
(10) Remove the front and rear oi l gal l ey pl ugs.
(11) Remove the oi l pump.
(12) Remove the connecti ng rods and the pi stons.
Remove the connecti ng rod and pi ston assembl i es
through the top of the cyl i nder bores.
(13) Remove the crankshaft.
Fig. 65 Measurement of Valve Guide Bore Diameter
GAUGE 9.525 MM (3/8 INCH) VALVE STEMGUIDE CYLINDER HEAD
Fig. 66 Measurement of Lateral Movement ofValve
Stem
DIAL INDICATOR
Fig. 67 Valve Spring Tester
TORQUE WRENCH VALVE SPRING TESTER
9 - 48 4. 0L ENGINE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) I nstal l the crankshaft.
(2) I nstal l the connecti ng rods and the pi stons
through the top of the cyl i nder bores.
(3) I nstal l the oi l pump.
(4) I nstal l the oi l pan and gasket.
(5) I nstal l the camshaft.
(6) I nstal l the sprockets and chai n as an assembl y.
(7) I nstal l the oi l sl i nger from the crankshaft.
(8) I nstal l the ti mi ng case cover seal .
(9) I nstal l the ti mi ng case cover.
(10) I nstal l the vi brati on damper.
(11) I nstal l the water pump. Ti ghten the mounti ng
bol ts to 31 Nm (23 ft. l bs.) torque.
(12) Lubri cate the oi l fi l ter seal wi th cl ean engi ne
oi l . Ti ghten oi l fi l ter to 18 Nm (156 i n. l bs.) torque.
(13) I nstal l the engi ne i nto the vehi cl e.
(14) Fi l l the engi ne wi th cl ean l ubri cati on oi l (refer
to Group 0, Lubri cati on and Mai ntenance).
(15) Fi l l the cool i ng system.
CLEANING AND INSPECTION
ENGINE CYLINDER HEAD
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
engi ne exhaust mani fol d and engi ne cyl i nder head
mati ng surfaces. Remove al l gasket materi al and car-
bon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
ENGINE CYLINDER HEAD COVER
CLEANING
Remove any ori gi nal seal er from the cover seal i ng
surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
Remove al l resi due from the seal i ng surface usi ng
a cl ean, dry cl oth.
INSPECTION
I nspect the engi ne cyl i nder head cover for cracks.
Repl ace the cover, i f cracked.
The ori gi nal dark grey gasket materi al shoul d
NOT be removed. I f secti ons of the gasket materi al
are mi ssi ng or are compressed, repl ace the engi ne
cyl i nder head cover. However, secti ons wi th mi nor
damage such as smal l cracks, cuts or chi ps may be
repai red wi th a hand hel d appl i cator. The new mate-
ri al must be smoothed over to mai ntai n gasket
hei ght. Al l ow the gasket materi al to cure pri or to
engi ne cyl i nder head cover i nstal l ati on.
ROCKER ARMS AND PUSH RODS
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
HYDRAULIC TAPPETS
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and defecti ve tap-
pets.
LEAK-DOWN TEST
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 68).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
ZG 4. 0L ENGINE 9 - 49
DISASSEMBLY AND ASSEMBLY (Continued)
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
CYLINDER BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 Nm (25 ft. l bs.) torque.
INSPECTIONCYLINDER BORE
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter (Fi g. 69). To
correctl y sel ect the proper si ze pi ston, a cyl i nder bore
gauge, capabl e of readi ng i n 0.003 mm (.0001 i n.)
I NCREMENTS i s requi red. I f a bore gauge i s not
avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
must be bored and then honed to accept an oversi ze
pi ston. A sl i ght amount of taper al ways exi sts i n the
Fig. 68 Leak-Down Tester
POINTER WEIGHTED ARM RAMCUP HANDLE PUSH ROD
Fig. 69 Cylinder Bore Measurement
FRONT MIDDLE OF BORE
USE FOR
SIZING
PISTON
9 - 50 4. 0L ENGINE ZG
CLEANING AND INSPECTION (Continued)
cyl i nder bore after the engi ne has been i n use for a
peri od of ti me.
HONINGCYLINDER BORE
The honi ng operati on shoul d be cl osel y coordi nated
wi th the fi tti ng of pi stons and ri ngs. Thi s wi l l ensure
speci fi ed cl earances are mai ntai ned.
Refer to Standard Servi ce Procedures i n the begi n-
ni ng of thi s Group for the proper honi ng of cyl i nder
bores.
SPECIFICATIONS
4. 0L ENGINE SPECIFICATIONS
Camshaft
Hydraul i c Tappet Cl earance . . . . . . . . . Zero Lash
Beari ng Cl earance . . . . . . . . . . 0.025 to 0.076 mm
(0.001 to 0.003 i n.)
Bearing J ournal Diameter
No. 1 . . . . . 51.54 to 51.56 mm (2.029 to 2.030 i n.)
No. 2 . . . . . 51.28 to 51.31 mm (2.019 to 2.020 i n.)
No. 3 . . . . . 51.03 to 51.05 mm (2.009 to 2.010 i n.)
No. 4 . . . . . 50.78 to 50.80 mm (1.999 to 2.000 i n.)
Base Ci rcl e Runout . . . . . . . . . . . 0.03 mm - max.
(0.001 i n. - max.)
Val ve Li ft . . . . . . . . . . . . . . . 10.29 mm (0.405 i n.)
Intake Valve Timing
Opens . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 BTDC
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . . 60.9 ABDC
Exhaust Valve Timing
Opens . . . . . . . . . . . . . . . . . . . . . . . . . 49.8 BBDC
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . . 29.2 ATDC
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . 42.6
I ntake Durati on . . . . . . . . . . . . . . . . . . . . . 253.3
Exhaust Durati on . . . . . . . . . . . . . . . . . . . . . 259.
Crankshaft
End Pl ay . . . . . . . . . . . . . . . . . 0.038 to 0.165 mm
(0.0015 to 0.0065 i n.)
Mai n Beari ng Journal Di ameter
No. 1-6 . . . . . . . . . . . . . . . 63.489 to 63.502 mm
(2.4996 to 2.5001 i n.)
Mai n Beari ng Journal Di ameter
No. 7 . . . . . . . . . . . . . . . . 63.449 to 63.487 mm
(2.4980 to 2.4995 i n.)
Mai n Beari ng Journal Wi dth
No. 1 . . . . . . . . . . . . . . . . . . 27.58 to 27.89 mm
(1.086 to 1.098 i n.)
Mai n Beari ng Journal Wi dth
No. 3 . . . . . . . . . . . . . . . . . . 32.28 to 32.33 mm
(1.271 to 1.273 i n.)
Mai n Beari ng Journal Wi dth
No. 2-4-5-6-7 . . . . . . . . . . . . 30.02 to 30.18 mm
(1.182 to 1.188 i n.)
Mai n Beari ng Cl earance . . . . . . . 0.03 to 0.06 mm
(0.001 to 0.0025 i n.)
Mai n Beari ng Cl earance
(Preferred) . . . . . . . . . . . . 0.051 mm (0.002 i n.)
Connecti ng Rod Journal
Di ameter . . . . . . . . . . . . . . . 53.17 to 53.23 mm
(2.0934 to 2.0955 i n.)
Connecti ng Rod Journal
Wi dth . . . . . . . . . . . . . . . . . . 27.18 to 27.33 mm
(1.070 to 1.076 i n.)
Out-of-Round (Max. Al l Journal s) . . . . . 0.013 mm
(0.0005 i n.)
Taper (Max. Al l Journal s) . . . . . . . . . . 0.013 mm
(0.0005 i n.)
Cylinder Block
Deck Hei ght . . . . . . . . . . . . . 240.03 to 240.18 mm
(9.450 to 9.456 i n.)
Deck Cl earance (Bel ow Bl ock) . . . . . . . . 0.546 mm
(0.0215 i n.)
Cyl i nder Bore Di ameter
Standard . . . . . . . . . . . . . . . 98.45 to 98.48 mm
(3.8759 to 3.8775 i n.)
Cyl i nder Bore Di ameter
Taper (Max.) . . . . . . . . . . . 0.025 mm (0.001 i n.)
Cyl i nder Bore Di ameter
Out-of-Round . . . . . . . . . . 0.025 mm (0.001 i n.)
Tappet Bore Di ameter . . . . . 23.000 to 23.025 mm
(0.9055 to 0.9065 i n.)
Fl atness . . . . . . . . . . . . . . . . 0.03 mm per 25 mm
(0.001 i n. per 1 i n.)
Fl atness . . . . . . . . . . . . . . . 0.05 mm per 152 mm
(0.002 i n. per 6 i n.)
Fl atness Max. . . . . 0.20 mm max. for total l ength
(0.008 i n. max. for total l ength)
Mai n Beari ng Bore
Di ameter . . . . . . . . . . . 68.3514 to 68.3768 mm
(2.691 to 2.692 i n.)
Connecting Rods
Total Wei ght (Less Beari ng) . . . 657 to 665 grams
(23.17 to 23.45 oz.)
Length (Center-to-Center) . . 155.52 to 155.62 mm
(6.123 to 6.127 i n)
Pi ston Pi n Bore Di ameter . . . . 23.59 to 23.62 mm
(0.9288 to 0.9298 i n.)
Bore (Less Beari ngs) . . . . . . . . 56.08 to 56.09 mm
(2.2080 to 2.2085 i n.)
Beari ng Cl earance . . . . . . . . . . 0.025 to 0.076 mm
(0.001 to 0.003 i n.)
Beari ng Cl earance (Preferred) . 0.044 to 0.050 mm
(0.0015 to 0.0020 i n.)
Si de Cl earance . 0.25 to 0.48 mm (0.010 to 0.019 i n.)
Twi st (Max.) . . . . . . . . . . . . . . . 0.001 mm per mm
(0.001 i n. per i nch)
Bend (Max.) . . . . . . . . . . . . . . . 0.001 mm per mm
(0.001 i n. per i nch.)
ZG 4. 0L ENGINE 9 - 51
CLEANING AND INSPECTION (Continued)
Cylinder Compression Pressure
Rati o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7:1
Pressure Range . . . . . . . . . . . . . 827 to 1,034 kPa
(120 to 150 psi )
Max. Vari ati on Between Cyl i nders . . . . . . 206 kPa
(30 psi )
Cylinder Head
Combusti on Chamber . . . . . . . . . 52.22 to 58.22 cc
(3.37 to 3.55 cu. i n.)
Val ve Gui de I .D. (I ntegral ) . . . . 7.9 mm (0.312 i n.)
Val ve Stem-to-Gui de Cl earance . 0.025 to 0.076 mm
(0.001 to 0.003 i n.)
I ntake Val ve Seat Angl e . . . . . . . . . . . . . . . . 44.5
Exhaust Val ve Seat Angl e . . . . . . . . . . . . . . . 44.5
Val ve Seat Wi dth . . . . . . . . . . . . . 1.02 to 1.52 mm
(0.040 to 0.060 i n.)
Val ve Seat Runout . . . . . . . 0.064 mm (0.0025 i n.)
Fl atness . . . . . . . . . . . . . . . . 0.03 mm per 25 mm
(0.001 i n. per 1 i n.)
Fl atness . . . . . . . . . . . . . . . 0.05 mm per 152 mm
(0.002 i n. per 6 i n.)
Fl atness Max. . . . 0.20 mm - max. for total l ength
(0.008 i n. max. for total l ength)
Rocker Arms, Push Rods & Tappets
Rocker Arm Rati o . . . . . . . . . . . . . . . . . . . . . 1.6:1
Push Rod Length . . . . . . . 244.856 to 245.364 mm
(9.640 to 9.660 i n.)
Push Rod Di ameter . . . . . . . . . . . 7.92 to 8.00 mm
(0.312 to 0.315 i n.)
Hydraul i c Tappet Di ameter . 22.962 to 22.974 mm
(0.904 to 0.9045 i n.)
Tappet-to-Bore Cl earance . . . . 0.025 to 0.063 mm
(0.001 to 0.0025 i n.)
Valves
Length (Ti p-to-Gauge Di mensi on
Li ne) I ntake . . . . . . . . . 122.479 to 122.860 mm
(4.822 to 4.837 i n.)
Length (Ti p-to-Gauge Di mensi on
Li ne) Exhaust . . . . . . . . 122.860 to 123.241 mm
(4.837 to 4.852 i n.)
Val ve Stem Di ameter . . . . . . . . 7.899 to 7.925 mm
(0.311 to 0.312 i n.)
Stem-to-Gui de Cl earance . . . . . 0.025 to 0.076 mm
(0.001 to 0.003 i n.)
Val ve Head Di ameter
I ntake . . . . . . . . . . . . . . . 48.387 to 48.641 mm
(1.905 to 1.915 i n.)
Val ve Head Di ameter
Exhaust . . . . . . . . . . . . . . 37.973 to 38.227 mm
(1.495 to 1.505 i n.)
Val ve Face Angl eI ntake . . . . . . . . . . . . . . . . 45
Val ve Face Angl eExhaust . . . . . . . . . . . . . . . 45
Ti p Refi ni shi ng (Max. Al l owabl e) . . . . . . 0.25 mm
(0.010 i n.)
Valve Springs
Free Length (Approx.) . . . . . 47.65 mm (1.876 i n.)
Spri ng Tensi onVal ve
Cl osed . . . . . . . . . . . 271 to 307 N @ 41.656 mm
(61 to 69 l bf. @ 1.64 i n.)
Spri ng Tensi onVal ve
Open . . . . . . . . . . 818.5 to 871.9 N @ 30.89 mm
(184 to 196 l bf @ 1.216 i n.)
I nsi de Di ameter . . . . . . . . . 21.0 mm to 21.51 mm
(0.827 to 0.847 i n.)
Pistons
Wei ght (Less Pi n) . . . . . . . . . . . 563 to 567 grams
(19.86 to 20.00 oz.)
Pi ston Pi n Bore (Centerl i ne to
Pi ston Top) . . . . . . . . . . . . . . 40.61 to 40.72 mm
(1.599 to 1.603 i n.)
Pi ston-to-Bore Cl earance . . . . . 0.033 to 0.053 mm
(0.0013 to 0.0021 i n.)
Pi ston-to-Bore Cl earance
(Preferred) . . . . . . . . . . . . . . 0.033 to 0.038 mm
(0.0013 to 0.0015 i n.)
Ri ng Gap Cl earance Top
Compressi on Ri ng . . . . . . . . . 0.229 to 0.610mm
(0.0090 to 0.0240 i n.)
Ri ng Gap Cl earance 2nd
Compressi on Ri ng . . . . . . . . 0.483 to 0.965 mm
(0.0190 to 0.0380 i n.)
Ri ng Gap Cl earanceOi l Control
Steel Rai l s . . . . . . . . . . . . . . 0.254 to 1.500 mm
(0.010 to 0.060 i n.)
Ri ng Si de Cl earanceCompressi on
Ri ngs . . . . . . . . . . . . . . . . . . 0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Ri ng Si de Cl earanceOi l Control
Ri ngs . . . . . . . . . . . . . . . . . . . . 0.06 to 0.21 mm
(0.0024 to 0.0083 i n.)
Pi ston Ri ng Groove Hei ght
Compressi on Ri ngs . . . . . . . 1.530 to 1.555 mm
(0.0602 to 0.0612 i n.)
Pi ston Ri ng Groove Hei ghtOi l
Control Ri ng . . . . . . . . . . . . 4.035 to 4.060 mm
(0.1589 to 0.1598 i n.)
Pi ston Ri ng Groove Di ameter
Compressi on Ri ngs . . . . . . . . 88.3 to 88.55 mm
(3.476 to 3.486 i n.)
Pi ston Ri ng Groove Di ameter
Oi l Control Ri ng . . . . . . . . . 90.35 to 90.60 mm
(3.557 to 3.566 i n.)
Pi ston Pi n Bore
Di ameter . . . . . . . . . . . . . 23.647 to 23.655 mm
(0.9310 to 0.9313 i n.)
Pi ston Pi n Di ameter . . . . . . . 23.637 to 23.640 mm
(0.9306 to 0.9307 i n.)
Pi ston-to-Pi n Cl earance . . 0.0076 to 0.0178 mm
Loose (0.0003 to 0.0007 i n. Loose)
9 - 52 4. 0L ENGINE ZG
SPECIFICATIONS (Continued)
Pi ston-to-Pi n Cl earance
(Preferred) . . . . . . . . . . . . . . . . . . . . . 0.013 mm
(0.0005 i n.)
Pi ston-to-Pi n Connecti ng Rod
(Press Fi t) . . . . . . . . . . . . . . 8.9 kN (2000 l bf.)
Oil Pump
Gear-to-Body Cl earance
(Radi al ) . 0.051 to 0.102 mm (0.002 to 0.004 i n.)
Gear-to-Body Cl earance (Radi al )
(Preferred) . . . . . . . . . . . . 0.051 mm (0.002 i n.)
Gear End Cl earance
Pl asti gage . 0.051 to 0.152 mm (0.002 to 0.006 i n.)
Gear End Cl earance
l asti gage (Preferred) . . . . . 0.051 mm (0.002 i n.)
Gear End Cl earanceFeel er
Gauge . . . . . . . . . . . . . . . 0.1016 to 0.2032 mm
(0.004 to 0.008 i n.)
Gear End Cl earanceFeel er
Gauge (Preferred) . . . . . . 0.1778 mm (0.007 i n.)
Oil Pressure
At I dl e Speed (600 rpm) . . . . . . . 89.6 kPa (13 psi )
At 1600 rpm & Hi gher . . . . . . . . . 255 to 517 kPa
(37 to 75 psi )
Oi l Pressure Rel i ef . . . . . . . . . . . 517 kPa (75 psi )
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
A/C Compressor Bracket-to-Engine
Bol ts . . . . . . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
A/C Compressor
Mounti ng Bol ts . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
A/C Low Pressure Service Valve
Nut . . . . . . . . . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
Block Heater
Nut . . . . . . . . . . . . . . . . . . . . . . .2 Nm (16 i n. l bs.)
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Clutch Cover to Flywheel
Bol ts . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Coil Bracket to Block
Bol ts . . . . . . . . . . . . . . . . . . . .22 Nm (192 i n. l bs.)
Connecting Rod
Nuts . . . . . . . . . . . . . . . . . . . . .45 Nm (33 ft. l bs.)
Cylinder Block
Drai n Pl ugs . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Cylinder Head
Bol ts #110 & #1214 . . . . . .149 Nm (110 ft. l bs.)
Bol t #11. . . . . . . . . . . . . . . . . . .135 Nm (100 ft. l bs.)
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . . .10 Nm (85 i n. l bs.)
Distributor Clamp
Bol t . . . . . . . . . . . . . . . . . . . . .23 Nm (204 i n. l bs.)
Engine MountsFront
Support Bracket Bol ts . . . . . . . .61 Nm (45 ft. l bs.)
Support Cushi on Bol ts/Nuts . . .41 Nm (30 ft. l bs.)
DESCRIPTION TORQUE
Support Cushi on Bracket
Bol ts . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Support Cushi on Bracket Stud Nuts . . . . . .41 Nm
(30 ft. l bs.)
Support Cushi on Thru-Bol t . . . .65 Nm (48 ft. l bs.)
Engine MountsRear
Crossmember-to-Si l l Bol ts (Automati c) . . . .41 Nm
(30 ft. l bs.)
I nsul ator Stud Assembl y Nut . .41 Nm (30 ft. l bs.)
Support Cushi on/Crossmember Nuts. . . . . .22 Nm
(192 i n. l bs.)
Support Cushi on/Bracket Nuts
(Manual ) . . . . . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Transmi ssi on Support Bracket Bol t
(Manual ). . . . . . . . . . . . . . . .46 Nm (34 ft. l bs.)
Transmi ssi on Support Bracket/Cushi on
Bol t (4WD Auto). . . . . . . . . . 75 Nm (55 ft. l bs.)
Transmi ssi on Support Adaptor Bracket
Bol ts (2WD Auto) . . . . . . . . . 75 Nm (55 ft. l bs.)
Exhaust Manifold/Pipe
Nuts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Flywheel/Converter Housing
Bol ts . . . . . . . . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
Flywheel/Crankshaft
Bol ts . . . . . . . . . . . . . . . . . . .143 Nm (105 ft. l bs.)
Front Cover-to-Block
Bol ts 1/420 . . . . . . . . . . . . . . . .7 Nm (60 i n. l bs.)
Bol ts 5/1618 . . . . . . . . . . . . .22 Nm (192 i n. l bs.)
Fuel Rail
Bol ts/Stud . . . . . . . . . . . . . . . .12 Nm (108 i n. l bs.)
Generator
Fi xed Bol t . . . . . . . . . . . . . . . . .24 Nm (18 ft. l bs.)
Thru Bol t/Nut . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
Main Bearing
Bol ts . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Oil Filter
Fi l ter . . . . . . . . . . . . . . . . . . . .18 Nm (156 i n. l bs.)
Connector (to adaptor). . . . . . . .47 Nm (35 ft. l bs.)
Connector (to bl ock). . . . . . . . . .68 Nm (50 ft. l bs.)
Adaptor Bol ts . . . . . . . . . . . . .102 Nm (50 ft. l bs.)
Oil Galley
Pl ug. . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Oil Pan
1/420 Bol ts . . . . . . . . . . . . . . .10 Nm (84 i n. l bs.)
5/1618 Bol ts . . . . . . . . . . . . .15 Nm (132 i n. l bs.)
Drai n Pl ug. . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Oil Pump
Short Attachi ng Bol ts . . . . . . . .23 Nm (17 ft. l bs.)
Long Attachi ng Bol ts . . . . . . . . .23 Nm (17 ft. l bs.)
Cover Bol ts . . . . . . . . . . . . . . . . .8 Nm (70 i n. l bs.)
Power Steering Pump Pressure Hose
Nut . . . . . . . . . . . . . . . . . . . . . .52 Nm (38 ft. l bs.)
Rocker ArmAssembly-to-Cylinder Head
Capscrews. . . . . . . . . . . . . . . . . .28 Nm (21ft. l bs.)
ZG 4. 0L ENGINE 9 - 53
SPECIFICATIONS (Continued)
DESCRIPTION TORQUE
Spark Plugs
Pl ugs . . . . . . . . . . . . . . . . . . . . .37 Nm (27 ft. l bs.)
Starter Motor
Mounti ng Bol ts . . . . . . . . . . . . .45 Nm (33 ft. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . .18 Nm (156 i n. l bs.)
Throttle Body
Bol ts . . . . . . . . . . . . . . . . . . . . .10 Nm (90 i n.l bs.)
Vibration Damper
Bol ts . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Water Pump/Block
Bol ts . . . . . . . . . . . . . . . . . . . . .31 Nm (23 ft. l bs.)
SPECIAL TOOLS
SPECIAL TOOLS
Valve Spring Compressor Tool MD-998772A
Timing Case Cover Alignment and Sealinstallation
Tool 6139
Vibration Damper Removal Tool 7697
Rear Main Seal Installer Tool 6271A
9 - 54 4. 0L ENGINE ZG
SPECIFICATIONS (Continued)
5.2L ENGINE
INDEX
page page
GENERAL INFORMATION
OIL PUMP PRESSURE . . . . . . . . . . . . . . . . . . . 56
PISTON AND CONNECTING ROD ASSEMBLY . 56
VALVES AND VALVE SPRINGS . . . . . . . . . . . . 56
DESCRIPTION AND OPERATION
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . 60
ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . 56
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . 57
SERVICE PROCEDURES
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . 62
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 62
FITTING CONNECTING ROD BEARINGS . . . . . 62
FITTING PISTON RINGS . . . . . . . . . . . . . . . . . 61
FITTING PISTONS . . . . . . . . . . . . . . . . . . . . . . 61
MEASURING TIMING CHAIN STRETCH . . . . . . 60
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 60
REMOVAL AND INSTALLATION
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . 71
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . 72
CRANKSHAFT REAR OIL SEALS . . . . . . . . . . . 76
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 75
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . 65
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 66
DISTRIBUTOR DRIVE SHAFT BUSHING . . . . . 72
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 64
ENGINE CORE OIL AND CAMSHAFT PLUGS . 78
ENGINE MOUNTSFRONT . . . . . . . . . . . . . . . 63
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . 64
FRONT CRANKSHAFT OIL SEAL . . . . . . . . . . . 76
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 68
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PISTON AND CONNECTING ROD ASSEMBLY . 74
ROCKER ARMS AND PUSH RODS . . . . . . . . . 66
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . 68
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 70
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE . . . . . . . . . . . . 66
VALVES AND VALVE SPRINGS . . . . . . . . . . . . 67
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . 68
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 81
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 79
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 79
CLEANING AND INSPECTION
CRANKSHAFT JOURNALS . . . . . . . . . . . . . . . 82
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 84
CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . 82
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
PISTON AND CONNECTING ROD ASSEMBLY . 82
SPECIFICATIONS
5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SPECIAL TOOLS
5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 85
GENERAL INFORMATION
VALVES AND VALVE SPRINGS
The val ves are arranged i n-l i ne and i ncl i ned 18.
The rocker pi vot support and the val ve gui des are
cast i ntegral wi th the heads.
OIL PUMP PRESSURE
The MI NI MUM oi l pump pressure i s 41.4 kPa (6
psi ) at curb i dl e. The MAXI MUM oi l pump pressure
i s 207-552 kPa (30-80 psi ) at 3,000 RPM or more.
CAUTION: If oil pressure is ZERO at curb idle, DO
NOT run engine.
PISTON AND CONNECTING ROD ASSEMBLY
The pi stons are el l i pti cal l y turned so that the
di ameter at the pi n boss i s l ess than i ts di ameter
across the thrust face. Thi s al l ows for expansi on
under normal operati ng condi ti ons. Under operati ng
temperatures, expansi on forces the pi n bosses away
from each other, causi ng the pi ston to assume a more
nearl y round shape.
Al l pi stons are machi ned to the same wei ght,
regardl ess of si ze, to mai ntai n pi ston bal ance.
The pi ston pi n rotates i n the pi ston onl y and i s
retai ned by the press i nterference fi t of the pi ston
pi n i n the connecti ng rod.
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION
The 5.2 Li ter (318 CI D) ei ght-cyl i nder engi ne i s a
V-Type l i ghtwei ght, si ngl e cam, overhead val ve
engi ne wi th hydraul i c rol l er tappets.
ZG 5. 2L ENGINE 9 - 55
Thi s engi ne i s desi gned for unl eaded fuel .
Engi ne type . . . . . . . . . . . . . . . . . . . . . 90 V-8 OHV
Bore and Stroke . . . 99.3 x 84.0 mm (3.91 x 3.31 i n.)
Di spl acement . . . . . . . . . . . . . . . . . . . 5.2L (318 c.i .)
Compressi on Rati o . . . . . . . . . . . . . . . . . . . . . . 9.1:1
Torque . . . . . . . . 386 Nm (285 ft. l bs.) @ 3,600 rpm
Fi ri ng Order . . . . . . . . . . . . . . . . . 18436572
Lubri cati on . . . Pressure FeedFul l Fl ow Fi l trati on
Engi ne Oi l Capaci ty . . . . . . . . 4.7L (5.0 qts.) w/fi l ter
Cool i ng System . Li qui d Cool edForced Ci rcul ati on
Cool i ng Capaci ty . . . . . . . . . . . . . . . 14.1L (14.9 qts.)
Cyl i nder Bl ock . . . . . . . . . . . . . . . . . . . . . . Cast I ron
Crankshaft . . . . . . . . . . . . . . . . . . . . . Nodul ar I ron
Cyl i nder Head . . . . . . . . . . . . . . . . . . . . . . Cast I ron
Combusti on Chambers . . . . Wedge-Hi gh Swi rl Val ve
Shroudi ng
Camshaft . . . . . . . . . . . . . . . . . . . Nodul ar Cast I ron
Pi stons . . . . . . . . . . . . . . . . Al umi num Al l oy w/Strut
Connecti ng Rods . . . . . . . . . . . . . . . . . . Forged Steel
Engi ne l ubri cati on system consi sts of a rotor type
oi l pump and a ful l fl ow oi l fi l ter.
The cyl i nders are numbered from front to rear; 1,
3, 5, 7 on the l eft bank and 2, 4, 6, 8 on the ri ght
bank. The fi ri ng order i s 1-8-4-3-6-5-7- 2 (Fi g. 1).
The engi ne seri al number i s stamped i nto a
machi ned pad l ocated on the l eft, front corner of the
cyl i nder bl ock. When component part repl acement i s
necessary, use the engi ne type and seri al number for
reference (Fi g. 2).
LUBRICATION SYSTEM
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the rear mai n beari ng
cap. The pump draws oi l through the screen and
i nl et tube from the sump at the rear of the oi l pan.
The oi l i s dri ven between the dri ve and i dl er gears
and pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength on the ri ght si de of the
bl ock. The oi l then goes down to the No. 1 mai n bear-
i ng, back up to the l eft si de of the bl ock and i nto the
oi l gal l ery on the l eft si de of the engi ne.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s to the connecti ng rod journal s.
Each connecti ng rod beari ng has hal f a hol e i n i t, oi l
passes through the hol e when the rods rotate and the
hol e l i nes up, oi l i s then thrown off as the rod
rotates. Thi s oi l throw off l ubri cates the camshaft
l obes, di stri butor dri ve gear, cyl i nder wal l s, and pi s-
ton pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. The camshaft beari ngs
recei ve oi l from the mai n beari ng gal l eri es. The front
camshaft beari ng journal passes oi l through the cam-
shaft sprocket to the ti mi ng chai n. Oi l drai ns back to
the oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components.
The oi l then passes down through the push rod gui de
hol es, and the oi l drai n back passages i n the cyl i nder
head past the val ve tappet area, and returns to the
oi l pan.
Fig. 1 Firing Order
CLOCKWISE ROTATION 18436572 FRONT OF ENGINE
Fig. 2 Engine Identification Number
9 - 56 5. 2L ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
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ZG 5. 2L ENGINE 9 - 57
DESCRIPTION AND OPERATION (Continued)
ENGINE COMPONENTS
CYLINDER HEAD
The al l oy cast i ron cyl i nder heads (Fi g. 4) are hel d
i n pl ace by 10 bol ts. The spark pl ugs are l ocated i n
the peak of the wedge between the val ves.
The 5.2L cyl i nder head i s i denti fi ed by the foundry
mark NH.
PISTONS
Al l pi stons are machi ned to the same wei ght,
regardl ess of si ze, to mai ntai n pi ston bal ance.
The pi stons are el l i pti cal l y turned so that the
di ameter at the pi n boss i s l ess than i ts di ameter
across the thrust face. Thi s al l ows for expansi on
under normal operati ng condi ti ons. Under operati ng
temperatures, expansi on forces the pi n bosses away
from each other, causi ng the pi ston to assume a more
nearl y round shape.
The pi ston pi n rotates i n the pi ston onl y and i s
retai ned by the press i nterference fi t of the pi ston
pi n i n the connecti ng rod.
SERVICE PROCEDURES
VALVE TIMING
(1) Turn crankshaft unti l the No.6 exhaust val ve i s
cl osi ng and No.6 i ntake val ve i s openi ng.
(2) I nsert a 6.350 mm (1/4 i nch) spacer between
rocker arm pad and stem ti p of No.1 i ntake val ve.
Al l ow spri ng l oad to bl eed tappet down gi vi ng i n
effect a sol i d tappet.
(3) I nstal l a di al i ndi cator so pl unger contacts
val ve spri ng retai ner as nearl y perpendi cul ar as pos-
si bl e. Zero the i ndi cator.
(4) Rotate the crankshaft cl ockwi se (normal run-
ni ng di recti on) unti l the val ve has l i fted 0.863 mm
(0.034 i nch). The ti mi ng of the crankshaft shoul d
now read from 10 before top dead center to 2 after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.
I f readi ng i s not wi thi n speci fi ed l i mi ts:
Check sprocket i ndex marks.
I nspect ti mi ng chai n for wear.
Check accuracy of DC mark on ti mi ng i ndi cator.
MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing
Chain Cover in Removal and Installation Section.
(1) Pl ace a scal e next to the ti mi ng chai n so that
any movement of the chai n may be measured.
(2) Pl ace a torque wrench and socket over cam-
shaft sprocket attachi ng bol t. Appl y torque i n the
di recti on of crankshaft rotati on to take up sl ack; 41
Nm (30 ft. l bs.) torque wi th cyl i nder head i nstal l ed
or 20 Nm (15 ft. l bs.) torque wi th cyl i nder head
removed. Wi th a torque appl i ed to the camshaft
sprocket bol t, crankshaft shoul d not be permi tted to
move. I t may be necessary to bl ock the crankshaft to
prevent rotati on.
(3) Hol d a scal e wi th di mensi onal readi ng even
wi th the edge of a chai n l i nk. Wi th cyl i nder heads
i nstal l ed, appl y 14 Nm (30 ft. l bs.) torque i n the
reverse di recti on. Wi th the cyl i nder heads removed,
appl y 20 Nm (15 ft. l bs.) torque i n the reverse di rec-
ti on. Note the amount of chai n movement (Fi g. 5).
(4) I nstal l a new ti mi ng chai n, i f i ts movement
exceeds 3.175 mm (1/8 i nch).
(5) I f chai n i s not sati sfactory, remove camshaft
sprocket attachi ng bol t and remove ti mi ng chai n wi th
crankshaft and camshaft sprockets.
(6) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on exact
i magi nary center l i ne through both camshaft and
crankshaft bores.
(7) Pl ace ti mi ng chai n around both sprockets.
Fig. 4 Cylinder Head Assembly
EXHAUST VALVE SPARK PLUGS EXHAUST VALVES SPARK PLUGS EXHAUST VALVE INTAKE VALVES INTAKE VALVES
Fig. 5 Measuring Timing Chain Wear and Stretch
TORQUE WRENCH
3.175 MM
(0.125 IN.)
9 - 58 5. 2L ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
(8) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(9) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed).
(10) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 6).
(11) I nstal l the camshaft bol t. Ti ghten the bol t to
47 Nm (35 ft. l bs.) torque.
(12) Check camshaft end pl ay. The end pl ay shoul d
be 0.051-0.152 mm (0.002-0.006 i nch) wi th a new
thrust pl ate and up to 0.254 mm (0.010 i nch) wi th a
used thrust pl ate. I f not wi thi n these l i mi ts i nstal l a
new thrust pl ate.
FITTING PISTONS
Pi ston and cyl i nder wal l must be cl ean and dry.
Speci fi ed cl earance between the pi ston and the cyl i n-
der wal l i s 0.013-0.038 mm (0.0005-0.0015 i nch) at
21C (70F).
Pi ston di ameter shoul d be measured at the top of
ski rt, 90 to pi ston pi n axi s l ocati on A i n (Fi g. 7). Cyl -
i nder bores shoul d be measured hal fway down the
cyl i nder bore and transverse to the engi ne crankshaft
center l i ne.
Pi stons and cyl i nder bores shoul d be measured at
normal room temperature, 21C (70F).
FITTING PISTON RINGS
(1) Measurement of end gaps:
(a) Measure pi ston ri ng gap 2 i nches from bot-
tom of cyl i nder bore. An i nverted pi ston can be
used to push the ri ngs down to ensure posi ti oni ng
ri ngs squarel y i n the cyl i nder bore before measur-
i ng.
(b) I nsert feel er gauge i n the gap. The top com-
pressi on ri ng gap shoul d be between 0.254-0.508
mm (0.010-0.020 i nch). The second compressi on
ri ng gap shoul d be between 0.508-0.762 mm (0.020-
0.030 i nch). The oi l ri ng gap shoul d be 0.254-1.270
mm (0.010-0.050 i nch).
(c) Ri ngs wi th i nsuffi ci ent end gap may be prop-
erl y fi l ed to the correct di mensi on. Ri ngs wi th
excess gaps shoul d not be used.
(2) I nstal l ri ngs and confi rm ri ng si de cl earance:
(a) I nstal l oi l ri ngs bei ng careful not to ni ck or
scratch the pi ston. I nstal l the oi l control ri ngs
accordi ng to i nstructi ons i n the package. I t i s not
necessary to use a tool to i nstal l the upper and
l ower rai l s. I nsert oi l rai l spacer fi rst, then si de
rai l s.
(b) I nstal l the second compressi on ri ngs usi ng
I nstal l ati on Tool C-4184. The compressi on ri ngs
must be i nstal l ed wi th the i denti fi cati on mark face
up (toward top of pi ston) and chamfer faci ng down.
An i denti fi cati on mark on the ri ng i s a dri l l poi nt,
a stamped l etter O, an oval depressi on or the
word TOP (Fi g. 8) (Fi g. 10).
(c) Usi ng a ri ng i nstal l er, i nstal l the top com-
pressi on ri ng wi th the chamfer faci ng up (Fi g. 9)
(Fi g. 10). An i denti fi cati on mark on the ri ng i s a
dri l l poi nt, a stamped l etter O, an oval depressi on
or the word TOP faci ng up.
(d) Measure si de cl earance between pi ston ri ng
and ri ng l and. Cl earance shoul d be 0.074-0.097 mm
(0.0029-0.0038 i nch) for the compressi on ri ngs. The
steel rai l oi l ri ng shoul d be free i n groove, but
Fig. 6 Alignment of Timing Marks
TIMING MARKS
Fig. 7 Piston Measurements
PISTON PIN BORE DIAMETER 25.007 25.015 mm (.9845 .9848 IN.) 62.230 mm (2.45 IN.) RING GROOVE HEIGHT OIL RAIL GROOVE 4.0309 4.0538 mm (.1587 .1596 IN.) COMPRESSION RAIL GROOVE 2.0294 2.0548 mm (.0799 .0809 IN.) TOTAL WEIGHT (FINISHED) 594.6 2 GRAMS
PISTON
SIZE
A DIA = PISTON DIAMETER BORE DIAMETER
MIN. mm (IN.) MAX. mm (IN.) MIN. mm (IN.) MAX. mm (IN.)
ZG 5. 2L ENGINE 9 - 59
SERVICE PROCEDURES (Continued)
shoul d not exceed 0.246 mm (0.0097 i nch) si de
cl earance.
(e) Pi stons wi th i nsuffi ci ent or excessi ve si de
cl earance shoul d be repl aced.
FITTING CONNECTING ROD BEARINGS
Fi t al l rods on a bank unti l compl eted. DO NOT
al ternate from one bank to another, because connect-
i ng rods and pi stons are not i nterchangeabl e from
one bank to another.
The beari ng caps are not i nterchangeabl e and
shoul d be marked at removal to ensure correct
assembl y.
Each beari ng cap has a smal l V-groove across the
parti ng face. When i nstal l i ng the l ower beari ng shel l ,
make certai n that the V-groove i n the shel l i s i n l i ne
wi th the V-groove i n the cap. Thi s provi des l ubri ca-
ti on of the cyl i nder wal l i n the opposi te bank.
The beari ng shel l s must be i nstal l ed so that the
tangs are i n the machi ned grooves i n the rods and
caps.
Li mi ts of taper or out-of-round on any crankshaft
journal s shoul d be hel d to 0.025 mm (0.001 i nch).
Beari ngs are avai l abl e i n 0.025 mm (0.001 i nch),
0.051 mm (0.002 i nch), 0.076 mm (0.003 i nch), 0.254
mm (0.010 i nch) and 0.305 mm (0.012 i nch) under-
si ze. Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
NOT file the rods or bearing caps.
CRANKSHAFT MAIN BEARINGS
Beari ng caps are not i nterchangeabl e and shoul d
be marked at removal to ensure correct assembl y.
Upper and l ower beari ng hal ves are NOT i nter-
changeabl e. Lower mai n beari ng hal ves of No.2 and 4
are i nterchangeabl e.
Upper and l ower No.3 beari ng hal ves are fl anged
to carry the crankshaft thrust l oads. They are NOT
i nterchangeabl e wi th any other beari ng hal ves i n the
engi ne (Fi g. 12). Beari ng shel l s are avai l abl e i n stan-
dard and the fol l owi ng undersi zes: 0.25 mm (0.001
i nch), 0.051 mm (0.002 i nch), 0.076 mm (0.003 i nch),
0.254 mm (0.010 i nch) and 0.305 mm (0.012 i nch).
Never i nstal l an undersi ze beari ng that wi l l reduce
cl earance bel ow speci fi cati ons.
CRANKSHAFT
A crankshaft whi ch has undersi ze journal s wi l l be
stamped wi th 1/4 i nch l etters on the mi l l ed fl at on
the No.8 crankshaft counterwei ght (Fi g. 13).
FOR EXAMPLE: R2 stamped on the No.8 crank-
shaft counterwei ght i ndi cates that the No.2 rod jour-
Fig. 8 Second Compression Ring
Identification(Typical)
SECOND COMPRESSION RING (BLACK CAST IRON) CHAMFER TWO DOTS
Fig. 9 Top Compression Ring Identification(Typical)
TOP COMPRESSION RING (GRAY IN COLOR) CHAMFER ONE DOT
Fig. 10 Compression Ring Chamfer
Location(Typical)
CHAMFER TOP COMPRESSION RING SECOND COMPRES- SION RING PISTON CHAMFER
Fig. 11 Proper Ring Installation
OIL RING SPACER GAP SECOND COM- PRESSION RING GAP OIL RING RAIL GAP (TOP) OIL RING RAIL GAP (BOTTOM) TOP COMPRES- SION RING GAP
9 - 60 5. 2L ENGINE ZG
SERVICE PROCEDURES (Continued)
nal i s 0.025 mm (0.001 i n) undersi ze. M4 i ndi cates
that the No.4 mai n journal i s 0.025 mm (0.001 i n)
undersi ze. R3 M2 i ndi cates that the No.3 rod journal
and the No.2 mai n journal are 0.025 mm (0.001 i n)
undersi ze.
When a crankshaft i s repl aced, al l mai n and con-
necti ng rod beari ngs shoul d be repl aced wi th new
beari ngs. Therefore, sel ecti ve fi tti ng of the beari ngs
i s not requi red when a crankshaft and beari ngs are
repl aced.
REMOVAL AND INSTALLATION
ENGINE MOUNTSFRONT
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Posi ti on fan to assure cl earance for radi ator top
tank and hose.
CAUTION: DO NOT lift the engine by the intake
manifold.
(3) I nstal l engi ne l i fti ng fi xture.
(4) Rai se vehi cl e on hoi st.
(5) Remove the engi ne support i nsul ator thru-bol ts
and nuts (Fi g. 14) (Fi g. 15).
(6) Rai se engi ne SLI GHTLY. Remove the engi ne
support i nsul ator bol ts. Remove the engi ne support
i nsul ator assembl y.
(7) I f requi red, remove the si l l bracket assembl y.
INSTALLATION
(1) I f the si l l bracket assembl y was removed,
i nstal l the bracket to the si l l assembl y.
Fig. 12 Main Bearing Identification
UPPER LOWER
Fig. 13 Location of Crankshaft Identification
Undersize Journal Identification Stamp 0.025 mm (0.001 in.) (Rod) 0.025 mm (0.001 in.) (Main) R1R2R3 or R4 M1M2M3M4 or M5 R-12 (ROD) M-1 (MAIN) 1/4 LETTERS #8 CRANKSHAFT COUNTERWEIGHT
Fig. 14 Front Engine MountRight Side
SILL BRACKET ASSEMBLY ENGINE SUP- PORT INSULA- TOR ASM. THROUGH-BOLT RIGHT SIDE
Fig. 15 Front Engine MountLeft Side
ENGINE SUPPORT INSULATOR ASM. TOP BOLTS BOTTOM BOLTS SIDE BOLTS SILL BRACKET ASSEMBLY THROUGH-BOLT LEFT SIDE
ZG 5. 2L ENGINE 9 - 61
SERVICE PROCEDURES (Continued)
(a) RI GHT SI DEI nstal l the si l l bracket assem-
bl y onto the si l l assembl y (Fi g. 14). I nstal l and
ti ghten the bol ts to 65 Nm (48 ft. l bs.) torque.
(b) LEFT SI DEI nstal l the si l l bracket assem-
bl y onto the si l l assembl y (Fi g. 15). I nstal l and
ti ghten the 2 top bol ts to 65 Nm (48 ft. l bs.)
torque. I nstal l and ti ghten the 2 si de bol ts to 95
Nm (70 ft. l bs.) torque. I nstal l and ti ghten the 2
bottom bol ts to 121 Nm (89 ft. l bs.) torque.
(2) Wi th the engi ne rai sed SLI GHTLY, posi ti on
engi ne support i nsul ator assembl y onto the engi ne
bl ock (Fi g. 14) (Fi g. 15). I nstal l bol ts and ti ghten to
88 Nm (65 ft. l bs.) torque.
(3) Lower engi ne wi th l i fti ng fi xture whi l e al i gni ng
engi ne support i nsul ator assembl y i nto si l l bracket
assembl y.
(4) I nstal l the thru-bol t and nut. Ti ghten the
RI GHT SI DE nut to 81 Nm (60 ft. l bs.) torque.
Ti ghten the LEFT SI DE nut to 81 Nm (60 ft. l bs.)
torque.
(5) Lower the vehi cl e.
(6) Remove l i fti ng fi xture.
(7) Connect the negati ve cabl e to the battery.
ENGINE MOUNTREAR
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Rai se the vehi cl e on a hoi st.
(3) Support the transmi ssi on wi th a jack.
(4) Remove stud nuts attachi ng engi ne mount to
crossmember (Fi g. 16). Remove mount.
(5) Rai se the transmi ssi on and engi ne SLI GHTLY.
(6) Remove engi ne mount bracket thru-bol t (Fi g.
16).
(7) Remove the engi ne mount assembl y from the
adaptor (Fi g. 16).
(8) I f requi red, remove the transmi ssi on support
bracket adaptor.
INSTALLATION
(1) Posi ti on the rear mount bracket onto the
exhaust hanger (i f previ ousl y removed). Posi ti on the
rear mount bracket assembl y onto the transmi ssi on
and i nstal l the bol ts. Ti ghten the bol ts to 46 Nm (34
ft. l bs.).
(2) Posi ti on mount i nto mount bracket and i nstal l
thru-bol t and nut. DO NOT ti ghten the bol t at thi s
ti me.
(3) Lower the transmi ssi on unti l the mount fasten-
i ng studs are i n posi ti on i n the crossmember.
(4) Remove transmi ssi on jack.
(5) I nstal l the mount fasteni ng nuts and ti ghten
the nuts to 54 Nm (40 ft. l bs.) torque.
(6) Ti ghten the thru-bol t nut to 65 Nm (48 ft. l bs.)
torque.
(7) Lower the vehi cl e.
(8) Connect the negati ve cabl e to the battery.
ENGINE ASSEMBLY
REMOVAL
(1) Scri be hood hi nge outl i nes on hood and remove
the hood.
(2) Remove the battery.
(3) Drai n cool i ng system.
(4) Remove the ai r cl eaner and tube.
(5) Set fan shroud asi de.
(6) Remove radi ator and heater hoses. Remove the
radi ator (refer to Group 7, Cool i ng System).
(7) Remove the vacuum l i nes.
(8) Remove the di stri butor cap and wi ri ng.
(9) Di sconnect the accel erator l i nkage.
(10) Perform the Fuel System Pressure Rel ease
procedure (refer to Group 14, Fuel System).
(11) Remove throttl e body.
(12) Remove the starter wi res.
(13) Remove the oi l pressure wi re.
(14) Di scharge the ai r condi ti oni ng system, i f
equi pped (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng for servi ce procedures).
(15) Remove ai r condi ti oni ng hoses.
(16) Di sconnect the power steeri ng hoses, i f
equi pped.
(17) Remove starter motor (refer to Group 8B, Bat-
tery/Starter Servi ce).
(18) Remove the generator (refer to Group 8C,
Generator Servi ce).
(19) Rai se and support the vehi cl e on a hoi st.
(20) Di sconnect exhaust pi pe at mani fol d.
Fig. 16 Rear Engine MountV-8
TRANS. ASSY.
BRACKET
CROSSMEMBER
9 - 62 5. 2L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(21) Support automati c transmi ssi on wi th a trans-
mi ssi on stand. Thi s wi l l assure that the torque con-
verter wi l l remai n i n proper posi ti on i n the
transmi ssi on housi ng.
(22) Remove bel l housi ng bol ts and i nspecti on
pl ate. Attach C-cl amp on front bottom of transmi s-
si on torque converter housi ng to prevent torque con-
verter from comi ng out.
(23) Remove torque converter dri ve pl ate bol ts
from torque converter dri ve pl ate. Mark converter
and dri ve pl ate to ai d i n assembl y.
(24) Di sconnect the engi ne from the torque con-
verter dri ve pl ate.
CAUTION: DO NOT lift the engine by the intake
manifold.
(25) I nstal l an engi ne l i fti ng fi xture.
(26) Remove the engi ne front mount thru-bol ts.
(27) Lower the vehi cl e.
(28) Remove engi ne from engi ne compartment.
(29) I nstal l on engi ne repai r stand.
INSTALLATION
(1) Remove engi ne from the repai r stand and posi -
ti on i n the engi ne compartment.
(2) I nstal l engi ne support fi xture.
(3) Rai se and support the vehi cl e on a hoi st.
(4) Posi ti on the torque converter and dri ve pl ate.
I nstal l torque converter dri ve pl ate bol ts. Ti ghten the
bol ts to 31 Nm (270 i n. l bs.) torque.
(5) I nstal l the engi ne front mount thru-bol ts.
(6) I nstal l bel l housi ng bol ts. Ti ghten the bol ts to
41 Nm (30 ft. l bs.) torque.
(7) Remove C-cl amp and i nstal l i nspecti on pl ate.
(8) Remove stand from transmi ssi on.
(9) I nstal l exhaust pi pe to mani fol d.
(10) Lower the vehi cl e.
(11) Remove engi ne l i fti ng fi xture.
(12) I nstal l the generator (refer to Group 8C, Gen-
erator Servi ce).
(13) I nstal l starter motor (refer to Group 8B, Bat-
tery/Starter Servi ce).
(14) I nstal l power steeri ng hoses, i f equi pped.
(15) I nstal l ai r condi ti oni ng hoses.
(16) Charge the ai r condi ti oner, i f equi pped (refer
to Group 24, Heater and Ai r Condi ti oni ng for servi ce
procedures).
(17) Usi ng a new gasket, i nstal l throttl e body.
Ti ghten the throttl e body bol ts to 23 Nm (200 i n.
l bs.) torque.
(18) Connect the accel erator l i nkage.
(19) Connect the starter wi res.
(20) Connect the oi l pressure wi re.
(21) I nstal l the di stri butor cap and wi ri ng.
(22) I nstal l vacuum l i nes.
(23) I nstal l radi ator, radi ator hoses and heater
hoses (refer to Group 7, Cool i ng System).
(24) I nstal l fan shroud i n posi ti on.
(25) I nstal l the battery
(26) Fi l l cool i ng system (refer to Group 7, Cool i ng
System for the proper procedure).
(27) I nstal l the ai r cl eaner.
(28) Warm engi ne and adjust.
(29) I nstal l hood and l i ne up.
(30) Road test vehi cl e.
CYLINDER HEAD COVER
A steel backed si l i con gasket i s used wi th the cyl -
i nder head cover (Fi g. 17). Thi s gasket can be used
agai n.
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Di sconnect cl osed venti l ati on system and evap-
orati on control system from cyl i nder head cover.
(3) On the l eft cover, remove the cool ant tube
bracket.
(4) Remove the i gni ti on wi res from the hol ders.
(5) Remove cyl i nder head cover and gasket. The
gasket may be used agai n.
(6) Cl ean cyl i nder head cover gasket surface.
(7) Cl ean head rai l , i f necessary.
INSTALLATION
(1) I nspect cover for di storti on and strai ghten, i f
necessary.
(2) Check the gasket for use i n head cover i nstal -
l ati on. I f damaged, use a new gasket.
(3) The cyl i nder head cover gasket can be used
agai n. I nstal l the gasket onto the head rai l .
(4) Posi ti on the cyl i nder head cover onto the gas-
ket. On the l eft cover, i nstal l the cool ant tube bracket
(refer to Group 7, Cool i ng System). Ti ghten the bol ts
to 11 Nm (95 i n. l bs.) torque.
(5) I nstal l the i gni ti on wi res onto the hol ders.
(6) I nstal l cl osed crankcase venti l ati on system and
evaporati on control system.
(7) Connect the negati ve cabl e to the battery.
Fig. 17 Cylinder Head Cover Gasket
CYLINDER HEAD COVER GASKET
ZG 5. 2L ENGINE 9 - 63
REMOVAL AND INSTALLATION (Continued)
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Di sconnect spark pl ug wi res by pul l i ng on the
boot strai ght out i n l i ne wi th pl ug.
(2) Remove cyl i nder head cover and gasket.
(3) Remove the rocker arm bol ts and pi vots (Fi g.
18). Pl ace them on a bench i n the same order as
removed.
(4) Remove the push rods and pl ace them on a
bench i n the same order as removed.
INSTALLATION
(1) Rotate the crankshaft unti l the V8 mark l i nes
up wi th the TDC mark on the ti mi ng chai n case
cover. Thi s mark i s l ocated 147 ATDC from the No.1
fi ri ng posi ti on.
(2) I nstal l the push rods i n the same order as
removed.
(3) I nstal l rocker arm and pi vot assembl i es i n the
same order as removed. Ti ghten the rocker arm bol ts
to 28 Nm (21 ft. l bs.) torque.
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) I nstal l cyl i nder head cover.
(5) Connect spark pl ug wi res.
VALVE SPRING AND STEM SEAL REPLACEMENT-
IN VEHICLE
(1) Set engi ne basi c ti mi ng to Top Dead Center
(TDC).
(2) Remove the ai r cl eaner.
(3) Remove cyl i nder head covers and spark pl ugs.
(4) Remove coi l wi re from di stri butor and secure to
good ground to prevent engi ne from starti ng.
(5) Usi ng sui tabl e socket and fl ex handl e at crank-
shaft retai ni ng bol t, turn engi ne so the No.1 pi ston i s
at TDC on the compressi on stroke.
(6) Remove rocker arms.
(7) Wi th ai r hose attached to an adapter i nstal l ed
i n No.1 spark pl ug hol e, appl y 620-689 kPa (90-100
psi ) ai r pressure.
(8) Usi ng Val ve Spri ng Compressor Tool
MD-998772A wi th adaptor 6633, compress val ve
spri ng and remove retai ner val ve l ocks and val ve
spri ng.
(9) I nstal l seal s on the exhaust val ve stem and
posi ti on down agai nst val ve gui des.
(10) The i ntake val ve stem seal s shoul d be pushed
fi rml y and squarel y over the val ve gui de usi ng the
val ve stem as a gui de. DO NOT force seal agai nst top
of gui de. When i nstal l i ng the val ve retai ner l ocks,
compress the spri ng onl y enough to i nstal l the l ocks.
(11) Fol l ow the same procedure on the remai ni ng 7
cyl i nders usi ng the fi ri ng sequence 1-8-4-3-6-5-7-2.
Make sure pi ston i n cyl i nder i s at TDC on the val ve
spri ng that i s bei ng removed.
(12) Remove adapter from the No.1 spark pl ug
hol e.
(13) I nstal l rocker arms.
(14) I nstal l covers and coi l wi re to di stri butor.
(15) I nstal l ai r cl eaner.
(16) Road test vehi cl e.
CYLINDER HEAD
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Drai n cool i ng system (refer to Group 7, Cool i ng
System for the proper procedures).
(3) Remove the generator.
(4) Remove cl osed crankcase venti l ati on system.
(5) Di sconnect the evaporati on control system.
(6) Remove the ai r cl eaner.
(7) Perform the Fuel System Pressure Rel ease pro-
cedure (refer to Group 14, Fuel System). Di sconnect
the fuel l i nes.
(8) Di sconnect accel erator l i nkage and i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(9) Remove the return spri ng.
(10) Remove di stri butor cap and wi res.
(11) Di sconnect the coi l wi res.
(12) Di sconnect heat i ndi cator sendi ng uni t wi re.
(13) Di sconnect heater hoses and bypass hose.
(14) Remove cyl i nder head covers and gaskets.
(15) Remove i ntake mani fol d and throttl e body as
an assembl y. Di scard the fl ange si de gaskets and the
front and rear cross-over gaskets.
(16) Remove exhaust mani fol ds.
(17) Remove rocker arm assembl i es and push rods.
I denti fy to ensure i nstal l ati on i n ori gi nal l ocati ons.
(18) Remove the head bol ts from each cyl i nder
head and remove cyl i nder heads. Di scard the cyl i n-
der head gasket.
(19) Remove spark pl ugs.
Fig. 18 Rocker Arms
ROCKER ARMS CYLINDERHEAD
9 - 64 5. 2L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on the new cyl i nder head gaskets onto
the cyl i nder bl ock.
(2) Posi ti on the cyl i nder heads onto head gaskets
and cyl i nder bl ock.
(3) Starti ng at top center, ti ghten al l cyl i nder head
bol ts, i n sequence, to 68 Nm (50 ft. l bs.) torque (Fi g.
19). Repeat procedure, ti ghten al l cyl i nder head bol ts
to 143 Nm (105 ft. l bs.) torque. Repeat procedure to
confi rm that al l bol ts are at 143 Nm (105 ft. l bs.)
torque.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) I nstal l push rods and rocker arm assembl i es i n
thei r ori gi nal posi ti on. Ti ghten the bol ts to 28 Nm
(21 ft. l bs.) torque.
(5) I nstal l the i ntake mani fol d and throttl e body
assembl y (refer to Group 11, Exhaust System and
I ntake Mani fol d).
(6) I nstal l exhaust mani fol ds. Ti ghten the bol ts
and nuts to 34 Nm (25 ft. l bs.) torque.
(7) Adjust spark pl ugs to speci fi cati ons (refer to
Group 8D, I gni ti on System). I nstal l the pl ugs and
ti ghten to 41 Nm (30 ft. l bs.) torque.
(8) I nstal l coi l wi res.
(9) Connect heat i ndi cator sendi ng uni t wi re.
(10) Connect the heater hoses and bypass hose.
(11) I nstal l di stri butor cap and wi res.
(12) Hook up the return spri ng.
(13) Connect the accel erator l i nkage and i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(14) I nstal l the fuel l i nes.
(15) I nstal l the generator and dri ve bel t. Ti ghten
generator mounti ng bol t to 41 Nm (30 ft. l bs.)
torque. Ti ghten the adjusti ng strap bol t to 23 Nm
(200 i n. l bs.) torque. Refer to Group 7, Cool i ng Sys-
tem for adjusti ng the bel t tensi on.
(16) I nstal l the i ntake mani fol d-to-generator
bracket support rod. Ti ghten the bol ts.
(17) Pl ace the cyl i nder head cover gaskets i n posi -
ti on and i nstal l cyl i nder head covers. Ti ghten the
bol ts to 11 Nm (95 i n. l bs.) torque.
(18) I nstal l cl osed crankcase venti l ati on system.
(19) Connect the evaporati on control system.
(20) I nstal l the ai r cl eaner.
(21) Fi l l cool i ng system (refer to Group 7, Cool i ng
System for proper procedure).
(22) Connect the negati ve cabl e to the battery.
VALVES AND VALVE SPRINGS
REMOVAL
(1) Remove the cyl i nder head.
(2) Compress val ve spri ngs usi ng Val ve Spri ng
Compressor Tool MD- 998772A.
(3) Remove val ve retai ni ng l ocks, val ve spri ng
retai ners, val ve stem seal s and val ve spri ngs.
(4) Before removi ng val ves, remove any burrs from
val ve stem l ock grooves to prevent damage to the
val ve gui des. I denti fy val ves to ensure i nstal l ati on i n
ori gi nal l ocati on.
INSTALLATION
(1) Cl ean val ves thoroughl y. Di scard burned,
warped and cracked val ves.
(2) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(3) Measure val ve stems for wear. I f wear exceeds
0.051 mm (0.002 i nch), repl ace the val ve.
(4) Coat val ve stems wi th l ubri cati on oi l and i nsert
them i n cyl i nder head.
(5) I f val ves or seats are reground, check val ve
stem hei ght. I f val ve i s too l ong, repl ace cyl i nder
head.
(6) I nstal l new seal s on al l val ve gui des. I nstal l
val ve spri ngs and val ve retai ners.
(7) Compress val ve spri ngs wi th Val ve Spri ng
Compressor Tool MD-998772A, i nstal l l ocks and
rel ease tool . I f val ves and/or seats are ground, mea-
sure the i nstal l ed hei ght of spri ngs. Make sure the
measurement i s taken from bottom of spri ng seat i n
cyl i nder head to the bottom surface of spri ng
retai ner. I f spacers are i nstal l ed, measure from the
top of spacer. I f hei ght i s greater than 42.86 mm
(1-11/16 i nches), i nstal l a 1.587 mm (1/16 i nch)
spacer i n head counterbore. Thi s shoul d bri ng spri ng
hei ght back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 i nch).
Fig. 19 Cylinder Head Bolt Tightening Sequence
FOUNDRY MARK NH
ZG 5. 2L ENGINE 9 - 65
REMOVAL AND INSTALLATION (Continued)
HYDRAULIC TAPPETS
REMOVAL
(1) Remove the ai r cl eaner.
(2) Remove cyl i nder head cover, rocker assembl y
and push rods. I denti fy push rods to ensure i nstal l a-
ti on i n ori gi nal l ocati on.
(3) Remove i ntake mani fol d, yoke retai ner and
al i gni ng yokes.
(4) Sl i de Hydraul i c Tappet Remover/I nstal l er Tool
C-4129-A through openi ng i n cyl i nder head and seat
tool fi rml y i n the head of tappet.
(5) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed, i denti fy tappets to
ensure i nstal l ati on i n ori gi nal l ocati on.
INSTALLATION
(1) I f the tappet or bore i n cyl i nder bl ock i s
scored, scuffed, or shows si gns of sti cki ng, ream the
bore to next oversi ze. Repl ace wi th oversi ze tappet.
(2) Lubri cate tappets.
(3) I nstal l tappets and push rods i n thei r ori gi nal
posi ti ons. Ensure that the oi l feed hol e i n the si de of
the tappet body faces up (away from the crankshaft).
(4) I nstal l al i gni ng yokes wi th ARROW toward
camshaft.
(5) I nstal l yoke retai ner. Ti ghten the bol ts to 23
Nm (200 i n. l bs.) torque. I nstal l i ntake mani fol d.
(6) I nstal l push rods i n ori gi nal posi ti ons.
(7) I nstal l rocker arm.
(8) I nstal l cyl i nder head cover.
(9) Start and operate engi ne. Warm up to normal
operati ng temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Remove fan shroud retai ner bol ts and set
shroud back over engi ne.
(3) Remove the cool i ng system fan.
(4) Remove the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(5) Remove the vi brati on damper pul l ey.
(6) Remove vi brati on damper bol t and washer from
end of crankshaft.
(7) I nstal l bar and screw from Pul l er Tool Set
C-3688. I nstal l 2 bol ts wi th washers through the
pul l er tool and i nto the vi brati on damper (Fi g. 20).
(8) Pul l vi brati on damper off of the crankshaft.
INSTALLATION
(1) Posi ti on the vi brati on damper onto the crank-
shaft.
(2) Pl ace i nstal l i ng tool , part of Pul l er Tool Set
C-3688 i n posi ti on and press the vi brati on damper
onto the crankshaft (Fi g. 21).
(3) I nstal l the crankshaft bol t and washer. Ti ghten
the bol t to 183 Nm (135 ft. l bs.) torque.
(4) I nstal l the crankshaft pul l ey. Ti ghten the pul -
l ey bol ts to 23 Nm (200 i n. l bs.) torque.
(5) I nstal l the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(6) I nstal l the cool i ng system fan. Ti ghten the
bol ts to 23 Nm (17 ft. l bs.) torque.
(7) Posi ti on the fan shroud and i nstal l the bol ts.
Ti ghten the retai ner bol ts to 11 Nm (95 i n. l bs.)
torque.
(8) Connect the negati ve cabl e to the battery.
TIMING CHAIN COVER
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Drai n cool i ng system (refer to Group 7, Cool i ng
System).
(3) Remove the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(4) Remove water pump (refer to Group 7, Cool i ng
System).
Fig. 20 Vibration Damper Assembly
SPECIAL TOOL C-3688
Fig. 21 Installing Vibration Damper
SPECIAL TOOL C-3688
9 - 66 5. 2L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(5) Remove power steeri ng pump (refer to Group
19, Steeri ng).
(6) Remove vi brati on damper.
(7) Loosen oi l pan bol ts and remove the front bol t
at each si de.
(8) Remove the cover bol ts.
(9) Remove chai n case cover and gasket usi ng
extreme cauti on to avoi d damagi ng oi l pan gasket.
(10) Pl ace a sui tabl e tool behi nd the l i ps of the oi l
seal to pry the oi l seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fi g. 22).
INSTALLATION
(1) Usi ng a new cover gasket, careful l y i nstal l
chai n case cover to avoi d damagi ng oi l pan gasket.
Use a smal l amount of Mopar Si l i cone Rubber Adhe-
si ve Seal ant, or equi val ent, at the joi nt between ti m-
i ng chai n cover gasket and the oi l pan gasket. Fi nger
ti ghten the ti mi ng chai n cover bol ts at thi s ti me.
(2) Pl ace the smal l er di ameter of the oi l seal over
Front Oi l Seal I nstal l ati on Tool 6635 (Fi g. 23). Seat
the oi l seal i n the groove of the tool .
(3) Posi ti on the seal and tool onto the crankshaft
(Fi g. 24).
(4) Ti ghten the 4 l ower chai n case cover bol ts to
13Nm (10 ft.l bs.) to prevent the cover from ti ppi ng
duri ng seal i nstal l ati on.
(5) Usi ng the vi brati on damper bol t, ti ghten the
bol t to draw the seal i nto posi ti on on the crankshaft
(Fi g. 25).
(6) Loosen the 4 bol ts ti ghtened i n step 4 to al l ow
real i gnment of front cover assembl y.
(7) Ti ghten chai n case cover bol ts to 41 Nm (30 ft.
l bs.) torque. Ti ghten oi l pan bol ts to 24 Nm (215 i n.
l bs.) torque.
(8) Remove the vi brati on damper bol t and seal
i nstal l ati on tool .
Fig. 22 Removal of Front Crankshaft Oil Seal
Fig. 23 Placing Oil Seal on InstallationTool 6635
CRANKSHAFT FRONT OIL SEAL INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 24 Position Tool and Seal onto Crankshaft
SPECIAL TOOL 6635 OIL SEAL TIMING CHAIN COVER
Fig. 25 Installing Oil Seal
SPECIAL TOOL 6635
TIMING
CHAIN
COVER
ZG 5. 2L ENGINE 9 - 67
REMOVAL AND INSTALLATION (Continued)
(9) I nstal l vi brati on damper.
(10) I nstal l water pump and housi ng assembl y
usi ng new gaskets (refer to Group 7, Cool i ng Sys-
tem). Ti ghten bol ts to 41 Nm (30 ft. l bs.) torque.
(11) I nstal l power steeri ng pump (refer to Group
19, Steeri ng).
(12) I nstal l the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(13) I nstal l the cool i ng system fan. Ti ghten the
bol ts to 23 Nm (17 ft. l bs.) torque.
(14) Posi ti on the fan shroud and i nstal l the bol ts.
Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
(15) Fi l l cool i ng system (refer to Group 7, Cool i ng
System for the proper procedure).
(16) Connect the negati ve cabl e to the battery.
TIMING CHAIN
REMOVAL
(1) Remove Ti mi ng Chai n Cover Refer to proce-
dure i n thi s secti on.
(2) Remove camshaft sprocket attachi ng bol t and
remove ti mi ng chai n wi th crankshaft and camshaft
sprockets.
INSTALLATION
(1) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on exact
i magi nary center l i ne through both camshaft and
crankshaft bores.
(2) Pl ace ti mi ng chai n around both sprockets.
(3) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(4) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed).
(5) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 26).
(6) I nstal l the camshaft bol t. Ti ghten the bol t to 68
Nm (50 ft. l bs.) torque.
(7) Check camshaft end pl ay. The end pl ay shoul d
be 0.051-0.152 mm (0.002-0.006 i nch) wi th a new
thrust pl ate and up to 0.254 mm (0.010 i nch) wi th a
used thrust pl ate. I f not wi thi n these l i mi ts i nstal l a
new thrust pl ate.
CAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 27).
REMOVAL
(1) Remove i ntake mani fol d.
(2) Remove cyl i nder head covers.
(3) Remove ti mi ng case cover and ti mi ng chai n.
(4) Remove rocker arms.
(5) Remove push rods and tappets. I denti fy each
part so i t can be i nstal l ed i n i ts ori gi nal l ocati on.
(6) Remove di stri butor and l i ft out the oi l pump
and di stri butor dri ve shaft.
(7) Remove camshaft thrust pl ate, note l ocati on of
oi l tab (Fi g. 28).
(8) I nstal l a l ong bol t i nto front of camshaft to
faci l i tate removal of the camshaft. Remove camshaft,
Fig. 26 Alignment of Timing Marks
TIMING MARKS
Fig. 27 Camshaft and Sprocket Assembly
THRUST PLATE OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL WITH CAMSHAFT CAMSHAFTSPROCKET
Fig. 28 Timing Chain Oil Tab Installation
THRUST PLATE FRONT SIDE CHAIN OIL TAB THRUST PLATE REAR SIDE
9 - 68 5. 2L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
bei ng careful not to damage cam beari ngs wi th the
cam l obes.
INSTALLATION
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft to wi thi n 51 mm (2
i nches) of i ts fi nal posi ti on i n cyl i nder bl ock.
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
Mopar Crankcase Conditioner, or equivalent. The oil
mixture should be left in engine for a minimum of
805 km (500 miles). Drain at the next normal oil
change.
(2) I nstal l Camshaft Gear I nstal l er Tool C-3509
wi th tongue back of di stri butor dri ve gear (Fi g. 29).
(3) Hol d tool i n posi ti on wi th a di stri butor l ock-
pl ate bol t. Thi s tool wi l l restri ct camshaft from bei ng
pushed i n too far and prevent knocki ng out the wel ch
pl ug i n rear of cyl i nder bl ock. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) I nstal l camshaft thrust pl ate and chai n oi l tab.
Make sure tang enters lower right hole in
thrust plate. Ti ghten bol ts to 24 Nm (210 i n. l bs.)
torque. Top edge of tab shoul d be fl at agai nst thrust
pl ate i n order to catch oi l for chai n l ubri cati on.
(5) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on exact
i magi nary center l i ne through both camshaft and
crankshaft bores.
(6) Pl ace ti mi ng chai n around both sprockets.
(7) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(8) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed).
(9) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 30).
(10) I nstal l the camshaft bol t/cup washer. Ti ghten
bol t to 68 Nm (50 ft. l bs.) torque.
(11) Measure camshaft end pl ay. Refer to Speci fi ca-
ti ons for proper cl earance. I f not wi thi n l i mi ts i nstal l
a new thrust pl ate.
(12) Each tappet reused must be i nstal l ed i n the
same posi ti on from whi ch i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) Wi th engi ne compl etel y di sassembl ed, dri ve out
rear cam beari ng core hol e pl ug.
(2) I nstal l proper si ze adapters and horseshoe
washers (part of Camshaft Beari ng Remover/I nstal l er
Tool C-3132-A) at back of each beari ng shel l . Dri ve
out beari ng shel l s (Fi g. 31).
INSTALLATION
(1) I nstal l new camshaft beari ngs wi th Camshaft
Beari ng Remover/I nstal l er Tool C-3132-A by sl i di ng
the new camshaft beari ng shel l over proper adapter.
Fig. 29 Camshaft Holding Tool C-3509
(InstalledPosition)
SPECIAL TOOL C-3509 DRIVE GEAR
DISTRIBUTOR LOCK BOLT
Fig. 30 Alignment of Timing Marks
TIMING MARKS
Fig. 31 Camshaft Bearings Removal/Installationwith
Tool C-3132-A
SPECIAL TOOL C-3132A MAIN BEARING OIL HOLE
ZG 5. 2L ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and i nstal l them
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) I denti fy beari ng caps before removal . Remove
beari ng caps one at a ti me.
(4) Remove upper hal f of beari ng by i nserti ng
Crankshaft Mai n Beari ng Remover/I nstal l er Tool
C-3059 i nto the oi l hol e of crankshaft (Fi g. 32).
(5) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
Onl y one mai n beari ng shoul d be sel ecti vel y fi tted
whi l e al l other mai n beari ng caps are properl y ti ght-
ened. Al l beari ng capbol ts removed duri ng servi ce
procedures are to be cl eaned and oi l ed before i nstal -
l ati on.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Crankshaft
Mai n Beari ng Remover/I nstal l er Tool C-3059 i nto oi l
hol e of crankshaft (Fi g. 32).
(2) Sl owl y rotate crankshaft countercl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Tool C-3059.
(3) I nstal l the beari ng caps. Cl ean and oi l the
bol ts. Ti ghten the capbol ts to 115 Nm (85 ft. l bs.)
torque.
(4) I nstal l the oi l pump.
(5) I nstal l the oi l pan.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove di stri butor, refer to Group 8D, I gni ti on
Systems for the proper procedure.
(2) Remove the i ntake mani fol d (refer to Group 11,
Exhaust System and I ntake Mani fol d).
(3) I nsert Di stri butor Dri ve Shaft Bushi ng Pul l er
Tool C-3052 i nto ol d bushi ng and thread down unti l a
ti ght fi t i s obtai ned (Fi g. 33).
(4) Hol d pul l er screw and ti ghten pul l er nut unti l
bushi ng i s removed.
INSTALLATION
(1) Sl i de new bushi ng over burni shi ng end of Di s-
tri butor Dri ve Shaft Bushi ng Dri ver/Burni sher Tool
C-3053. I nsert the tool and bushi ng i nto the bore.
(2) Dri ve bushi ng and tool i nto posi ti on, usi ng a
hammer (Fi g. 34).
(3) As the burni sher i s pul l ed through the bushi ng,
the bushi ng i s expanded ti ght i n the bl ock and bur-
ni shed to correct si ze (Fi g. 35). DO NOT ream this
bushing.
Fig. 32 Upper Main Bearing Removal and
Installationwith Tool C-3059
SPECIAL TOOL C-3059 BEARING SPECIAL TOOL C-3059 BEARING INSTALLING REMOVING
Fig. 33 Distributor Driveshaft Bushing Removal
SPECIAL TOOL C-3052 BUSHING
Fig. 34 Distributor Driveshaft Bushing Installation
SPECIAL TOOL C-3053 BUSHING
9 - 70 5. 2L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) I nstal l the i ntake mani fol d (refer to Group 11,
Exhaust System and I ntake Mani fol d).
DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil
pump drive shaft must be aligned to number one
cylinder.
(1) Rotate crankshaft unti l No.1 cyl i nder i s at top
dead center on the fi ri ng stroke.
(2) When i n thi s posi ti on, the ti mi ng mark of
vi brati on damper shoul d be under 0 on the ti mi ng
i ndi cator.
(3) I nstal l the shaft so that after the gear spi ral s
i nto pl ace, i t wi l l i ndex wi th the oi l pump shaft. The
sl ot on top of oi l pump shaft shoul d be al i gned
towards the l eft front i ntake mani fol d attachi ng bol t
hol e (Fi g. 36).
(4) I nstal l di stri butor, refer to Group 8D, I gni ti on
Systems for the proper procedure.
After the di stri butor has been i nstal l ed, i ts rota-
ti onal posi ti on must be set usi ng the SET SYNC
mode of the DRB scan tool . Refer to Checki ng Di s-
tri butor Posi ti on fol l owi ng the Di stri butor I nstal l a-
ti on secti on i n Group 8D, I gni ti on system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
effect fuel synchronization only.
OIL PAN
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Rai se the vehi cl e.
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Remove the oi l fi l ter.
(5) Remove the starter (refer to Group 8B, Battery/
Starter/Generator Servi ce).
(6) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(7) Posi ti on the cool er l i nes out of the way.
(8) Di sconnect the oxygen sensor.
(9) Remove exhaust pi pe.
(10) Remove the oi l pan bol ts. Careful l y sl i de the
oi l pan and gasket to the rear. I f equi pped wi th an oi l
l evel sensor, take care not to damage the sensor.
INSTALLATION
(1) Fabri cate 4 al i gnment dowel s from 5/16 x 1 1/2
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 37).
(2) I nstal l the dowel s i n the cyl i nder bl ock (Fi g.
38).
(3) Appl y smal l amount of Mopar Si l i cone Rubber
Adhesi ve Seal ant, or equi val ent i n the corner of the
cap and the cyl i nder bl ock.
(4) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock.
(5) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(6) I nstal l the oi l pan bol ts. Ti ghten the bol ts to 24
Nm (215 i n. l bs.) torque.
(7) Remove the dowel s. I nstal l the remai ni ng oi l
pan bol ts. Ti ghten these bol ts to 24 Nm (215 i n. l bs.)
torque.
Fig. 35 Burnishing Distributor DriveshaftBushing
SPECIAL TOOLC-3053 BUSHING
Fig. 36 Position of Oil Pump Shaft Slot
DISTRIBUTORDRIVE
Fig. 37 Fabrication of Alignment Dowels
5/16 X 1
1
2 BOLT DOWEL SLOT
ZG 5. 2L ENGINE 9 - 71
REMOVAL AND INSTALLATION (Continued)
(8) I nstal l the drai n pl ug. Ti ghten drai n pl ug to 34
Nm (25 ft. l bs.) torque.
(9) I nstal l exhaust pi pe.
(10) Connect the oxygen sensor.
(11) I nstal l the oi l fi l ter.
(12) I f equi pped wi th an oi l l evel sensor, connect
the sensor.
(13) I nstal l the starter (refer to Group 8B, Battery/
Starter/Generator Servi ce).
(14) Move the cool er l i nes back i nto posi ti on.
(15) Lower vehi cl e.
(16) Connect the negati ve cabl e to the battery.
(17) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(18) Start the engi ne and i nspect for l eaks.
PISTON AND CONNECTING ROD ASSEMBLY
REMOVAL
(1) Remove the engi ne from the vehi cl e.
(2) Remove the cyl i nder head.
(3) Remove the oi l pan.
(4) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pi stons covered
duri ng thi s operati on.
(5) Be sure the connecti ng rod and connecti ng rod
cap are i denti fi ed wi th the cyl i nder number. Remove
connecti ng rod cap. I nstal l connecti ng rod bol t gui de
set on connecti ng rod bol ts.
(6) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. When removi ng pi ston and
connecti ng rod assembl i es, rotate crankshaft to cen-
ter the connecti ng rod i n the cyl i nder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mat-
i ng rod.
INSTALLATION
(1) Be sure that compressi on ri ng gaps are stag-
gered so that nei ther i s i n-l i ne wi th oi l ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, make
sure the oi l ri ng expander ends are butted and the
rai l gaps l ocated properl y (Fi g. 39).
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l . Sl i de Pi ston Ri ng Compressor Tool C-385
over the pi ston and ti ghten wi th the speci al wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) I nstal l connecti ng rod bol t protectors on rod
bol ts, the l ong protector shoul d be i nstal l ed on the
numbered si de of the connecti ng rod.
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. Be sure
connecti ng rod and cyl i nder bore number are the
same. I nsert rod and pi ston i nto cyl i nder bore and
gui de rod over the crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on crankshaft journal .
(7) The notch or groove on top of pi ston must be
poi nti ng toward front of engi ne. The l arger chamfer
of the connecti ng rod bore must be i nstal l ed toward
crankshaft journal fi l l et.
Fig. 38 Position of Dowels in Cylinder Block
DOWEL DOWEL DOWEL DOWEL
Fig. 39 Proper Ring Installation
OIL RING SPACER GAP SECOND COM- PRESSION RING GAP OIL RING RAIL GAP (TOP) OIL RING RAIL GAP (BOTTOM) TOP COMPRES- SION RING GAP
9 - 72 5. 2L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(8) I nstal l rod caps. Be sure connecti ng rod, con-
necti ng rod cap and cyl i nder bore number are the
same. I nstal l nuts on cl eaned and oi l ed rod bol ts and
ti ghten nuts to 61 Nm (45 ft. l bs.) torque.
(9) I nstal l the oi l pan.
(10) I nstal l the cyl i nder head.
(11) I nstal l the engi ne i nto the vehi cl e.
CRANKSHAFT
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) Remove the vi brati on damper.
(4) Remove the ti mi ng chai n cover.
(5) I denti fy beari ng caps before removal . Remove
beari ng caps and beari ngs one at a ti me.
(6) Li ft the crankshaft out of the bl ock.
(7) Remove and di scard the crankshaft rear oi l
seal s.
(8) Remove and di scard the front crankshaft oi l
seal .
INSTALLATION
(1) Cl ean Locti te 518 resi due and seal ant from the
cyl i nder bl ock and rear cap mati ng surface. Do thi s
before appl yi ng the Locti te drop and the i nstal l ati on
of rear cap.
(2) Li ghtl y oi l the new upper seal l i ps wi th engi ne
oi l .
(3) I nstal l the new upper rear beari ng oi l seal wi th
the whi te pai nt faci ng towards the rear of the engi ne.
(4) Posi ti on the crankshaft i nto the cyl i nder bl ock.
(5) Li ghtl y oi l the new l ower seal l i ps wi th engi ne
oi l .
(6) I nstal l the new l ower rear beari ng oi l seal i nto
the beari ng cap wi th the whi te pai nt faci ng towards
the rear of the engi ne.
(7) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 40). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on.
(8) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(9) Cl ean and oi l al l cap bol ts. I nstal l al l mai n
beari ng caps. I nstal l al l cap bol ts and al ternatel y
ti ghten to 115 Nm (85 ft. l bs.) torque.
(10) I nstal l oi l pump.
(11) I nstal l the ti mi ng chai n cover.
(12) I nstal l the vi brati on damper.
(13) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent, at beari ng cap to bl ock joi nt to
provi de cap to bl ock and oi l pan seal i ng (Fi g. 41).
Appl y enough seal ant unti l a smal l amount i s
squeezed out. Wi thdraw nozzl e and wi pe excess seal -
ant off the oi l pan seal groove.
(14) I nstal l new front crankshaft oi l seal .
(15) I mmedi atel y i nstal l the oi l pan.
OIL PUMP
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from rear mai n beari ng
cap.
INSTALLATION
(1) I nstal l oi l pump. Duri ng i nstal l ati on sl owl y
rotate pump body to ensure dri veshaft-to-pump rotor
shaft engagement.
(2) Hol d the oi l pump base fl ush agai nst mati ng
surface on No.5 mai n beari ng cap. Fi nger ti ghten
pump attachi ng bol ts. Ti ghten attachi ng bol ts to 41
Nm (30 ft. l bs.) torque.
(3) I nstal l the oi l pan.
Fig. 40 Sealant Applicationto Bearing Cap
.25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR MAIN CAP
Fig. 41 Apply Sealant to Bearing Cap to BlockJoint
MOPAR SILICONE RUB- BER ADHESIVE SEALANT NOZZLE TIP SEALANT APPLIED CYLINDER BLOCK REAR MAIN BEAR- ING CAP
ZG 5. 2L ENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)
FRONT CRANKSHAFT OIL SEAL
The oi l seal can be repl aced wi thout removi ng the
ti mi ng chai n cover provi ded the cover i s not mi s-
al i gned.
(1) Di sconnect the negati ve cabl e from the battery.
(2) Remove vi brati on damper.
(3) I f front seal i s suspected of l eaki ng, check front
oi l seal al i gnment to crankshaft. The seal i nstal l a-
ti on/al i gnment tool 6635, shoul d fi t wi th mi ni mum
i nterference. I f tool does not fi t, the cover must be
removed and i nstal l ed properl y.
(4) Pl ace a sui tabl e tool behi nd the l i ps of the oi l
seal to pry the oi l seal outward. Be careful not to
damage the crankshaft seal bore of cover.
(5) Pl ace the smal l er di ameter of the oi l seal over
Front Oi l Seal I nstal l ati on Tool 6635 (Fi g. 42). Seat
the oi l seal i n the groove of the tool .
(6) Posi ti on the seal and tool onto the crankshaft
(Fi g. 43).
(7) Usi ng the vi brati on damper bol t, ti ghten the
bol t to draw the seal i nto posi ti on on the crankshaft
(Fi g. 44).
(8) Remove the vi brati on damper bol t and seal
i nstal l ati on tool .
(9) I nspect the seal fl ange on the vi brati on
damper.
(10) I nstal l the vi brati on damper.
(11) Connect the negati ve cabl e to the battery.
CRANKSHAFT REAR OIL SEALS
The servi ce seal i s a 2 pi ece, vi ton seal . The upper
seal hal f can be i nstal l ed wi th crankshaft removed
from engi ne or wi th crankshaft i nstal l ed. When a
new upper seal i s i nstal l ed, i nstal l a new l ower seal .
The l ower seal hal f can onl y be i nstal l ed wi th the
rear mai n beari ng cap removed.
UPPER SEAL CRANKSHAFT REMOVED
REMOVAL
(1) Remove the crankshaft. Di scard the ol d upper
seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock rear cap mati ng sur-
face. Make sure the seal groove i s free of debri s.
Fig. 42 Placing Oil Seal on InstallationTool 6635
CRANKSHAFT FRONT OIL SEAL INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 43 Position Tool and Sealonto Crankshaft
SPECIAL TOOL 6635 OIL SEAL TIMING CHAIN COVER
Fig. 44 Installing Oil Seal
SPECIAL TOOL 6635
TIMING
CHAIN
COVER
9 - 74 5. 2L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(2) Li ghtl y oi l the new upper seal l i ps wi th engi ne
oi l .
(3) I nstal l the new upper rear beari ng oi l seal wi th
the whi te pai nt faci ng towards the rear of the engi ne.
(4) Posi ti on the crankshaft i nto the cyl i nder bl ock.
(5) Li ghtl y oi l the new l ower seal l i ps wi th engi ne
oi l .
(6) I nstal l the new l ower rear beari ng oi l seal i nto
the beari ng cap wi th the whi te pai nt faci ng towards
the rear of the engi ne.
(7) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 45). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on.
(8) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(9) Cl ean and oi l al l cap bol ts. I nstal l al l mai n
beari ng caps. I nstal l al l cap bol ts and al ternatel y
ti ghten to 115 Nm (85 ft. l bs.) torque.
(10) I nstal l oi l pump.
(11) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent, at beari ng cap to bl ock joi nt to
provi de cap to bl ock and oi l pan seal i ng (Fi g. 46).
Appl y enough seal ant unti l a smal l amount i s
squeezed out. Wi thdraw nozzl e and wi pe excess seal -
ant off the oi l pan seal groove.
(12) I nstal l new front crankshaft oi l seal .
(13) I mmedi atel y i nstal l the oi l pan.
UPPER SEAL CRANKSHAFT INSTALLED
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) Remove the rear mai n beari ng cap. Remove
and di scard the ol d l ower oi l seal .
(4) Careful l y remove and di scard the ol d upper oi l
seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock mati ng surfaces before
oi l seal i nstal l ati on. Check for burr at the oi l hol e on
the cyl i nder bl ock mati ng surface to rear cap.
(2) Li ghtl y oi l the new upper seal l i ps wi th engi ne
oi l . To al l ow ease of i nstal l ati on of the seal , l oosen at
l east the 2 mai n beari ng caps forward of the rear
beari ng cap.
(3) Rotate the new upper seal i nto the cyl i nder
bl ock bei ng careful not to shave or cut the outer sur-
face of the seal . To assure proper i nstal l ati on, use the
i nstal l ati on tool provi ded wi th the ki t. I nstal l the
new seal wi th the whi te pai nt faci ng towards the
rear of the engi ne.
(4) I nstal l the new l ower rear beari ng oi l seal i nto
the beari ng cap wi th the whi te pai nt faci ng towards
the rear of the engi ne.
(5) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 45). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on. Be sure the whi te pai nt faces toward the rear
of the engi ne.
(6) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(7) I nstal l the rear mai n beari ng cap wi th cl eaned
and oi l ed cap bol ts. Al ternatel y ti ghten ALL cap bol ts
to 115 Nm (85 ft. l bs.) torque.
(8) I nstal l oi l pump.
(9) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant,
or equi val ent, at beari ng cap to bl ock joi nt to provi de
cap to bl ock and oi l pan seal i ng (Fi g. 46). Appl y
Fig. 45 Sealant Application to Bearing Cap
MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
LOCTITE 518 (OR EQUIVALENT) CAP ALIGNMENT SLOT REAR MAIN BEARING CAP
Fig. 46 Apply Sealant to Bearing Cap to BlockJoint
MOPAR SILICONE RUB- BER ADHESIVE SEALANT NOZZLE TIP SEALANT APPLIED CYLINDER BLOCK REAR MAIN BEAR- ING CAP
ZG 5. 2L ENGINE 9 - 75
REMOVAL AND INSTALLATION (Continued)
enough seal ant unti l a smal l amount i s squeezed out.
Wi thdraw nozzl e and wi pe excess seal ant off the oi l
pan seal groove.
(10) I mmedi atel y i nstal l the oi l pan.
LOWER SEAL
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) Remove the rear mai n beari ng cap and di scard
the ol d l ower seal .
INSTALLATION
(1) Cl ean the rear mai n cap mati ng surfaces
i ncl udi ng the oi l pan gasket groove.
(2) Careful l y i nstal l a new upper seal (refer to
Upper Seal Repl acement - Crankshaft I nstal l ed pro-
cedure above).
(3) Li ghtl y oi l the new l ower seal l i ps wi th engi ne
oi l .
(4) I nstal l a new l ower seal i n beari ng cap wi th
the whi te pai nt faci ng the rear of engi ne.
(5) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 45). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on.
(6) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(7) I nstal l the rear mai n beari ng cap wi th cl eaned
and oi l ed cap bol ts. Al ternatel y ti ghten the cap bol ts
to 115 Nm (85 ft. l bs.) torque.
(8) I nstal l oi l pump.
(9) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant,
or equi val ent, at beari ng cap to bl ock joi nt to provi de
cap to bl ock and oi l pan seal i ng (Fi g. 46). Appl y
enough seal ant unti l a smal l amount i s squeezed out.
Wi thdraw nozzl e and wi pe excess seal ant off the oi l
pan seal groove.
(10) I mmedi atel y i nstal l the oi l pan.
ENGINE CORE OIL AND CAMSHAFT PLUGS
Engi ne core pl ugs have been pressed i nto the oi l
gal l eri es behi nd the camshaft thrust pl ate (Fi g. 47).
Thi s wi l l reduce i nternal l eakage and hel p mai ntai n
hi gher oi l pressure at i dl e.
REMOVAL
(1) Usi ng a bl unt tool such as a dri ft or a screw-
dri ver and a hammer, stri ke the bottom edge of the
cup pl ug (Fi g. 48).
(2) Wi th the cup pl ug rotated, grasp fi rml y wi th
pl i ers or other sui tabl e tool and remove pl ug (Fi g.
48).
INSTALLATION
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Be certai n the new pl ug i s cl eaned of al l oi l or
grease.
(1) Coat edges of pl ug and core hol e wi th Mopar
Gasket Maker, or equi val ent.
CAUTION: DO NOT drive cup plug into the casting,
as restricted coolant flow can result and cause seri-
ous engine problems.
(2) Usi ng proper pl ug dri ve, dri ve cup pl ug i nto
hol e. The sharp edge of the pl ug shoul d be at l east
0.50 mm (0.020 i n.) i nsi de the l ead-i n chamfer.
Fig. 47 Location of Cup Plugs in Oil Galleries
CUP PLUGS
Fig. 48 Core Hole Plug Removal
CYLINDER BLOCK SECOND REMOVE PLUG WITH PLI- ERS FIRST STRIKE HERE WITH HAMMER DRIFT CUP PLUG
9 - 76 5. 2L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(3) I t i s not necessary to wai t for curi ng of the
seal ant. The cool i ng system can be fi l l ed and the
vehi cl e pl aced i n servi ce i mmedi atel y.
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis-
assemble a tappet on a dirty work bench.
DISASSEMBLE
(1) Pry out pl unger retai ner spri ng cl i p (Fi g. 49).
(2) Cl ean varni sh deposi ts from i nsi de of tappet
body above pl unger cap.
(3) I nvert tappet body and remove pl unger cap,
pl unger, check val ve, check val ve spri ng, check val ve
retai ner and pl unger spri ng (Fi g. 49). Check val ve
coul d be fl at or bal l .
ASSEMBLE
(1) Cl ean al l tappet parts i n a sol vent that wi l l
remove al l varni sh and carbon.
(2) Repl ace tappets that are unfi t for further ser-
vi ce wi th new assembl i es.
(3) I f pl unger shows si gns of scori ng or wear,
i nstal l a new tappet assembl y. I f val ve i s pi tted, or
val ve seat on end of pl unger i s prevented from seat-
i ng, i nstal l a new tappet assembl y.
(4) Assembl e tappets (Fi g. 49).
VALVE SERVICE
VALVE GUIDES
Measure val ve stem gui de cl earance as fol l ows:
(1) I nstal l Val ve Gui de Sl eeve Tool C-3973 over
val ve stem and i nstal l val ve (Fi g. 50). The speci al
sl eeve pl aces the val ve at the correct hei ght for
checki ng wi th a di al i ndi cator.
(2) Attach Di al I ndi cator Tool C-3339 to cyl i nder
head and set i t at ri ght angl e of val ve stem bei ng
measured (Fi g. 51).
(3) Move val ve to and from the i ndi cator. The total
di al i ndi cator readi ng shoul d not exceed 0.432 mm
(0.017 i nch). Ream the gui des for val ves wi th over-
si ze stems i f di al i ndi cator readi ng i s excessi ve or i f
the stems are scuffed or scored.
(4) Servi ce val ves wi th oversi ze stems are avai l -
abl e (Fi g. 52).
(5) Sl owl y turn reamer by hand and cl ean gui de
thoroughl y before i nstal l i ng new val ve. Ream the
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
seat:
Step 1Ream to 0.0763 mm (0.003 i nch).
Step 2Ream to 0.381 mm (0.015 i nch).
REFACING VALVES AND VALVE SEATS
The i ntake and exhaust val ves have a 43-1/4 to
43-3/4 face angl e and a 44-1/4 to 44-3/4 seat angl e
(Fi g. 53).
Fig. 49 Hydraulic Tappet Assembly
PLUNGERSPRING CHECK BALLPLUNGER PLUNGER RETAINER SPRING CLIP PLUNGER CAP CHECK VALVE SPRING RETAINER ROLLER TAP- PET BODY
Fig. 50 Positioning Valve with Tool C-3973
VALVE SPACER TOOL
Fig. 51 Measuring Valve Guide Wear
VALVE SPECIAL TOOL C-3339
ZG 5. 2L ENGINE 9 - 77
REMOVAL AND INSTALLATION (Continued)
VALVES
I nspect the remai ni ng margi n after the val ves are
refaced (Fi g. 54). Val ves wi th l ess than 1.190 mm
(0.047 i nch) margi n shoul d be di scarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 55).
(1) When refaci ng val ve seats, i t i s i mportant that
the correct si ze val ve gui de pi l ot be used for reseat-
i ng stones. A true and compl ete surface must be
obtai ned.
(2) Measure the concentri ci ty of val ve seat usi ng a
di al i ndi cator. Total runout shoul d not exceed 0.051
mm (0.002 i nch) total i ndi cator readi ng.
(3) I nspect the val ve seat wi th Prussi an bl ue to
determi ne where the val ve contacts the seat. To do
thi s, coat val ve seat LI GHTLY wi th Prussi an bl ue
then set val ve i n pl ace. Rotate the val ve wi th l i ght
pressure. I f the bl ue i s transferred to the center of
val ve face, contact i s sati sfactory. I f the bl ue i s trans-
ferred to the top edge of val ve face, l ower val ve seat
wi th a 15 stone. I f the bl ue i s transferred to bottom
edge of val ve face rai se val ve seat wi th a 60 stone.
(4) When seat i s properl y posi ti oned the wi dth of
i ntake seats shoul d be 1.016-1.524 mm (0.040-0.060
i nch). The wi dth of the exhaust seats shoul d be
1.524-2.032 mm (0.060-0.080 i nch).
VALVE SPRING INSPECTION
Whenever val ves have been removed for i nspecti on,
recondi ti oni ng or repl acement, val ve spri ngs shoul d
be tested. As an exampl e the compressi on l ength of
the spri ng to be tested i s 1-5/16 i nch. Turn tabl e of
Uni versal s Val ve Spri ng Tester Tool unti l surface i s
i n l i ne wi th the 1-5/16 i nch mark on the threaded
stud. Be sure the zero mark i s to the front (Fi g. 56).
Pl ace spri ng over stud on the tabl e and l i ft compress-
Fig. 52 Reamer Sizes
Fig. 53 Valve Face and Seat Angles
CONTACT POINT A SEAT WIDTH INTAKE 1.016 1.524 mm (0.040 0.060 in.) EXHAUST 1.524 2.032 mm (0.060 0.080 in.) B FACE ANGLE (INTAKE & EXHAUST) 43
1
4 43
3
4 C SEAT ANGLE (INTAKE & EXHAUST) 44
1
4 44
3
4 D CONTACT SURFACE
Fig. 54 Intake and Exhaust Valves
INTAKE VALVE MARGIN EXHAUST VALVE VALVE SPRING RETAINER LOCKGROOVE STEM
FACE
Fig. 55 Refacing Valve Seats
REFACING STONE
MUST NOT CUT VALVE
SHROUD
STONE
PILOT VALVE SEAT SHROUD
9 - 78 5. 2L ENGINE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l pi ng i s heard. Take readi ng on torque wrench
at thi s i nstant. Mul ti pl y thi s readi ng by 2. Thi s wi l l
gi ve the spri ng l oad at test l ength. Fracti onal mea-
surements are i ndi cated on the tabl e for fi ner adjust-
ments. Refer to speci fi cati ons to obtai n speci fi ed
hei ght and al l owabl e tensi ons. Di scard the spri ngs
that do not meet speci fi cati ons.
OIL PUMP
DISASSEMBLE
(1) Remove the rel i ef val ve as fol l ows:
(a) Remove cotter pi n. Dri l l a 3.175 mm (1/8
i nch) hol e i nto the rel i ef val ve retai ner cap and
i nsert a sel f-threadi ng sheet metal screw.
(b) Cl amp screw i nto a vi se and whi l e support-
i ng oi l pump, remove cap by tappi ng pump body
usi ng a soft hammer. Di scard retai ner cap and
remove spri ng and rel i ef val ve (Fi g. 57).
(2) Remove oi l pump cover (Fi g. 58).
(3) Remove pump outer rotor and i nner rotor wi th
shaft (Fi g. 58).
(4) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
ASSEMBLE
(1) I nstal l pump rotors and shaft, usi ng new parts
as requi red.
(2) Posi ti on the oi l pump cover onto the pump
body. Ti ghten cover bol ts to 11 Nm (95 i n. l bs.)
torque.
(3) I nstal l the rel i ef val ve and spri ng. I nsert the
cotter pi n.
(4) Tap on a new retai ner cap.
(5) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
CYLINDER BLOCK
DISASSEMBLE
Engi ne assembl y removed from vehi cl e:
(1) Remove the cyl i nder head.
(2) Remove the oi l pan.
(3) Remove the pi ston and connecti ng rod assem-
bl i es.
ASSEMBLE
(1) I nstal l the pi ston and connecti ng rod assembl y.
(2) I nstal l the oi l pan.
(3) I nstal l the cyl i nder head.
(4) I nstal l the engi ne i nto the vehi cl e.
CLEANING AND INSPECTION
CYLINDER HEADS
CLEANING
Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
Cl ean cyl i nder bl ock front and rear gasket surfaces
usi ng a sui tabl e sol vent.
Fig. 56 Testing Valve Spring for CompressedLength
TORQUE WRENCH VALVE SPRING TESTER
Fig. 57 Oil Pressure Relief Valve
OIL PUMP ASSEMBLY COTTER PIN RELIEF VALVE RETAINERCAP SPRING
Fig. 58 Oil Pump
INNER ROTOR AND SHAFT BODY DISTRIBUTOR DRIVESHAFT (REFERENCE) COTTER PIN RETAINERCAP SPRING RELIEF VALVE LARGE CHAMFERED EDGE BOLT COVER OUTERROTOR
ZG 5. 2L ENGINE 9 - 79
DISASSEMBLY AND ASSEMBLY (Continued)
INSPECTION
I nspect al l surfaces wi th a strai ghtedge i f there i s
any reason to suspect l eakage. I f out-of-fl atness
exceeds 0.00075 mm/mm (0.00075 i nch/i nch) ti mes
the span l ength i n i nches i n any di recti on, ei ther
repl ace head or l i ghtl y machi ne the head surface.
FOR EXAMPLE: A 305 mm (12 i nch) span i s 0.102
mm (0.004 i nch) out-of-fl at. The al l owabl e out-of-fl at i s
305 x 0.00075 (12 x 0.00075) equal s 0.23 mm (0.009
i nch). Thi s amount of out-of-fl at i s acceptabl e.
The cyl i nder head surface fi ni sh shoul d be
1.78-3.00 mi crons (70-125 mi cro i nches).
I nspect push rods. Repl ace worn or bent rods.
PISTON AND CONNECTING ROD ASSEMBLY
INSPECTION
Check the crankshaft connecti ng rod journal for
excessi ve wear, taper and scori ng.
Check the cyl i nder bl ock bore for out-of-round,
taper, scori ng and scuffi ng.
Check the pi stons for taper and el l i pti cal shape
before they are fi tted i nto the cyl i nder bore (Fi g. 59).
CRANKSHAFT JOURNALS
The crankshaft connecti ng rod and mai n journal s
shoul d be checked for excessi ve wear, taper and scor-
i ng. The maxi mum taper or out-of-round on any
crankshaft journal i s 0.025 mm (0.001 i nch).
Journal gri ndi ng shoul d not exceed 0.305 mm
(0.012 i nch) under the standard journal di ameter. DO
NOT gri nd thrust faces of No.3 mai n beari ng. DO
NOT ni ck crank pi n or beari ng fi l l ets. After gri ndi ng,
remove rough edges from crankshaft oi l hol es and
cl ean out al l oi l passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.
OIL PAN
CLEANING
Cl ean the bl ock and pan gasket surfaces.
Tri m or remove excess seal ant fi l m i n the rear
mai n cap oi l pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
I f present, tri m excess seal ant from i nsi de the engi ne.
Cl ean oi l pan i n sol vent and wi pe dry wi th a cl ean
cl oth.
Cl ean oi l screen and pi pe thoroughl y i n cl ean sol -
vent. I nspect condi ti on of screen.
INSPECTION
I nspect oi l drai n pl ug and pl ug hol e for stri pped or
damaged threads. Repai r as necessary.
I nspect oi l pan mounti ng fl ange for bends or di stor-
ti on. Strai ghten fl ange, i f necessary.
OIL PUMP
INSPECTION
Mati ng surface of the oi l pump cover shoul d be
smooth. Repl ace pump assembl y i f cover i s scratched
or grooved.
Lay a strai ghtedge across the pump cover surface
(Fi g. 60). I f a 0.038 mm (0.0015 i nch) feel er gauge
can be i nserted between cover and strai ghtedge,
pump assembl y shoul d be repl aced.
Fig. 59 Piston Measurements
PISTON PIN BORE DIAMETER 25.007 25.015 mm (.9845 .9848 IN.) 62.230 mm (2.45 IN.) RING GROOVE HEIGHT OIL RAIL GROOVE 4.0309 4.0538 mm (.1587 .1596 IN.) COMPRESSION RAIL GROOVE 2.0294 2.0548 mm (.0799 .0809 IN.) TOTAL WEIGHT (FINISHED) 594.6 2 GRAMS
PISTON
SIZE
A DIA = PISTON DIAMETER BORE DIAMETER
MIN. mm (IN.) MAX. mm (IN.) MIN. mm (IN.) MAX. mm (IN.)
Fig. 60 Checking Oil Pump Cover Flatness
COVER STRAIGHT EDGE FEELER GAUGE
9 - 80 5. 2L ENGINE ZG
CLEANING AND INSPECTION (Continued)
Measure thi ckness and di ameter of OUTER rotor.
I f outer rotor thi ckness measures 20.9 mm (0.825
i nch) or l ess or i f the di ameter i s 62.7 mm (2.469
i nches) or l ess, repl ace outer rotor (Fi g. 61).
I f i nner rotor measures 20.9 mm (0.825 i nch) or
l ess, repl ace i nner rotor and shaft assembl y (Fi g. 62).
Sl i de outer rotor i nto pump body. Press rotor to the
si de wi th your fi ngers and measure cl earance
between rotor and pump body (Fi g. 63). I f cl earance
i s 0.356 mm (0.014 i nch) or more, repl ace oi l pump
assembl y.
I nstal l i nner rotor and shaft i nto pump body. I f
cl earance between i nner and outer rotors i s 0.203
mm (0.008 i nch) or more, repl ace shaft and both
rotors (Fi g. 64).
Pl ace a strai ghtedge across the face of the pump,
between bol t hol es. I f a feel er gauge of 0.102 mm
(0.004 i nch) or more can be i nserted between rotors
and the strai ghtedge, repl ace pump assembl y (Fi g.
65).
I nspect oi l pressure rel i ef val ve pl unger for scori ng
and free operati on i n i ts bore. Smal l marks may be
removed wi th 400-gri t wet or dry sandpaper.
The rel i ef val ve spri ng has a free l ength of approx-
i matel y 49.5 mm (1.95 i nches). The spri ng shoul d
test between 19.5 and 20.5 pounds when compressed
Fig. 61 Measuring Outer Rotor Thickness
Fig. 62 Measuring Inner Rotor Thickness
Fig. 63 Measuring Outer Rotor Clearance inHousing
PUMP BODY OUTER ROTOR FEELER GAUGE
Fig. 64 Measuring Clearance Between Rotors
OUTER ROTOR FEELER GAUGE INNER ROTOR
Fig. 65 Measuring Clearance Over Rotors
STRAIGHT EDGE FEELER GAUGE
ZG 5. 2L ENGINE 9 - 81
CLEANING AND INSPECTION (Continued)
to 34 mm (1-11/32 i nches). Repl ace spri ng that fai l s
to meet these speci fi cati ons (Fi g. 66).
I f oi l pressure was l ow and pump i s wi thi n speci fi -
cati ons, i nspect for worn engi ne beari ngs or other
reasons for oi l pressure l oss.
CYLINDER BLOCK
CLEANING
Cl ean cyl i nder bl ock thoroughl y and check al l core
hol e pl ugs for evi dence of l eaki ng.
INSPECTION
Exami ne bl ock for cracks or fractures.
The cyl i nder wal l s shoul d be checked for out-of-
round and taper wi th Cyl i nder Bore I ndi cator Tool
C-119. The cyl i nder bl ock shoul d be bored and honed
wi th new pi stons and ri ngs fi tted i f:
The cyl i nder bores show more than 0.127 mm
(0.005 i n.) out-of-round.
The cyl i nder bores show a taper of more than
0.254 mm (0.010 i n.).
The cyl i nder wal l s are badl y scuffed or scored.
Bori ng and honi ng operati on shoul d be cl osel y coor-
di nated wi th the fi tti ng of pi stons and ri ngs, so that
speci fi ed cl earances can be mai ntai ned.
OIL LINE PLUG
The oi l l i ne pl ug i s l ocated i n the verti cal passage
at the rear of the bl ock between the oi l -to-fi l ter and
oi l -from-fi l ter passages (Fi g. 67). I mproper i nstal l a-
ti on or pl ug mi ssi ng coul d cause errati c, l ow, or no oi l
pressure.
The oi l pl ug must come out the bottom. Use fl at
dowel , down the oi l pressure sendi ng uni t hol e from
the top, to remove oi l pl ug.
(1) Remove oi l pressure sendi ng uni t from back of
bl ock.
(2) I nsert a 3.175 mm (1/8 i n.) fi ni sh wi re, or
equi val ent, i nto passage.
(3) Pl ug shoul d be 190.0 to 195.2 mm (7-1/2 to
7-11/16 i n.) from machi ned surface of bl ock (Fi g. 67).
I f pl ug i s too hi gh, use a sui tabl e fl at dowel to posi -
ti on properl y.
(4) I f pl ug i s too l ow, remove oi l pan and No. 4
mai n beari ng cap. Use sui tabl e fl at dowel to posi ti on
properl y. Coat outsi de di ameter of pl ug wi th Mopar
Stud and Beari ng Mount Adhesi ve, or equi val ent.
Pl ug shoul d be 54.0 to 57.7 mm (2-1/8 to 2-5/16 i n.)
from bottom of the bl ock.
Fig. 66 Proper Installation of Retainer Cap
RETAINER CAP CHAMFER COTTER KEY
Fig. 67 Oil Line Plug
RIGHT OIL GALLERY CYLINDER BLOCK OIL FROM FIL- TER TO SYS- TEM OIL TO FILTER FROM OIL PUMP CRANKSHAFT
PLUG
9 - 82 5. 2L ENGINE ZG
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
5. 2L ENGINE
Camshaft
Beari ng Di ameter
No. 1 . . . . . . . . . . . . . . . . . . . . 50.800 50.825 mm
(2.000 2.001 i n)
No. 2 . . . . . . . . . . . . . . . . . . . . 50.394 50.419 mm
(1.984 1.985 i n)
No. 3 . . . . . . . . . . . . . . . . . . . . 50.013 50.038 mm
(1.969 1.970 i n)
No. 4 . . . . . . . . . . . . . . . . . . . . 49.606 49.632 mm
(1.953 1.954 i n)
No. 5 . . . . . . . . . . . . . . . . . . . . 39.688 39.713 mm
(1.5625 1.5635 i n)
Di ametri cal Cl erance . . . . . . . 0.0254 0.0762 mm
(0.001 0.003 i n)
Max. Al l owabl e . . . . . . . . . . . . . 0.127 mm (0.005 i n)
End Pl ay . . . . . . . . . . . . . . . . . . . 0.051 0.254 mm
(0.002 0.010 i n)
Beari ng Journal Di ameter
No. 1 . . . . . . . . . . . . . . . . . . . . 50.749 50.775 mm
(1.998 1.999 i n)
No. 2 . . . . . . . . . . . . . . . . . . . . 50.343 50.368 mm
(1.982 1.983 i n)
No. 3 . . . . . . . . . . . . . . . . . . . . 49.962 49.987 mm
(1.967 1.968 i n)
No. 4 . . . . . . . . . . . . . . . . . . . . 49.555 49.581 mm
(1.951 1.952 i n)
No. 5 . . . . . . . . . . . . . . . . . . . . 39.637 39.662 mm
(1.5605 1.5615 i n)
Connecting Rods
Beari ng Cl earance . . . . . . . . . . . 0.013 0.056 mm
(0.0005 0.0022 i n)
Max. Al l owabl e . . . . . . . . . . . . . . 0.08 mm (0.003 i n)
Pi ston Pi n Bore Di ameter . . . . 24.966 24.978 mm
(0.9829 0.9834 i n)
Si de Cl earance (Two Rods) . . . . . 0.152 0.356 mm
(0.006 0.014 i n)
Total Wei ght (Less Beari ng) . . . . . . . . . . . 726 grams
(25.61 oz)
Crankshaft
Connect Rod Journal
Di ameter . . . . . . . . . . . . . . . . . 53.950 53.975 mm
(2.124 2.125 i n)
Out-of-Round (Max.) . . . . . . . . 0.0254 mm (0.001 i n)
Taper (Max.) . . . . . . . . . . . . . . 0.0254 mm (0.001 i n)
Di ametri cal Cl earance
No. 1 . . . . . . . . . . . . . . . . . . . . . . 0.013 0.038 mm
(0.0005 0.0015 i n)
Nos. 2, 3, 4 and 5 . . . . . . . . . . . . 0.013 0.051 mm
(0.005 0.0020 i n)
Max. Al l owabl e (Nos. 2, 3, 4 & 5) . . . . . . . 0.064 mm
(0.0025 i n)
End Pl ay . . . . . . . . . . . . . . . . . . . 0.051 0.178 mm
(0.002 0.007 i n)
Max. Al l owabl e . . . . . . . . . . . . . 0.254 mm (0.010 i n)
Mai n Beari ng Journal s
Di ameter . . . . . . . . . . . . . . . . . 63.487 63.513 mm
(2.4995 2.5005 i n)
Out-of-Round (Max.) . . . . . . . . 0.0254 mm (0.001 i n)
Taper (Max.) . . . . . . . . . . . . . . 0.0254 mm (0.001 i n)
Cylinder Block
Cyl i nder Bore
Di ameter . . . . . . . . . . . . . . . . . 99.314 99.365 mm
(3.910 3.912 i n)
Out-of-Round (Max.) . . . . . . . . . 0.127 mm (0.005 i n)
Taper (Max.) . . . . . . . . . . . . . . . 0.254 mm (0.010 i n)
Oversi ze (Max.) . . . . . . . . . . . . . 1.016 mm (0.040 i n)
Di stri butor Lower Dri ve Shaft Bushi ng
(Press Fi t i n Bl ock) . . . . . . . 0.0127 0.3556 mm
(0.0005 0.0140 i n)
Shaft-to-Bushi ng Cl earance . . 0.0178 0.0686 mm
(0.0007 0.0027 i n)
Tappet Bore Di ameter . . . . . . . . 22.99 23.01 mm
(0.9051 0.9059 i n)
Cylinder Head
Compressi on Pressure . . . . . . . . . 689 kPa (100 psi )
Gasket Thi ckness (Compressed) . . . . . . . 1.2065 mm
(0.0475 i n)
Val ve Seat
Angl e . . . . . . . . . . . . . . . . . . . . . . . . 44.25 44.75
Runout (Max.) . . . . . . . . . . . . . 0.0762 mm (0.003 i n)
Wi dth (Fi ni sh) I ntake . . . . . . . 1.016 1.524 mm
(0.040 0.060 i n)
Wi dth (Fi ni sh) Exhaust . . . . . 1.524 2.032 mm
(0.060 0.080 i n)
Hydraulic Tappets
Body Di ameter . . . . . . . . . . . . 22.949 22.962 mm
(0.9035 0.9040 i n)
Cl earance i n Bl ock . . . . . . . . . 0.0279 0.0610 mm
(0.0011 0.0024 i n)
Dry Lash . . . . . . . . . . . . . . . . . . 1.524 5.334 mm
(0.060 0.210 i n)
Push Rod Length . . . . . . . . . . 175.64 176.15 mm
(6.915 6.935 i n)
Oil Pump
Cl earance Over Rotors (Max.) . 0.1016 mm (0.004 i n)
Cover Out-of-Fl at (Max.) . . . . 0.0381 mm (0.0015 i n)
I nner Rotor Thi ckness (Mi n.) . 20.955 mm (0.825 i n)
Outer Rotor
Cl earance (Max.) . . . . . . . . . . . 0.3556 mm (0.014 i n)
Di ameter (Mi n.) . . . . . . . . . . 62.7126 mm (2.469 i n)
Thi ckness (Mi n.) . . . . . . . . . . . 20.955 mm (0.825 i n)
Ti p Cl earance Between Rotors
(Max.) . . . . . . . . . . . . . . . . . 0.2032 mm (0.008 i n)
Oil Pressure
At Curb I dl e Speed (Mi ni mum)* . . . 41.4 kPa (6 psi )
At 3000 rpm . . . . . . . . . 207 552 kPa (30 80 psi )
ZG 5. 2L ENGINE 9 - 83
Oi l Pressure Swi tch
Actuati ng Pressure (Mi n.) . . . . . . . 34.5 48.3 kPa
(5 7 psi )
*CAUTI ON: I f pressure i s ZERO at curb i dl e, DO NOT
run engi ne at 3,000 rpm.
Oil Filter
Bypass Val ve Setti ng . . . . . . . . . . . . . 62 103 kPa
(9 15 psi )
Pistons
Cl earance at Top of Ski rt . . . . 0.0127 0.0381 mm
(0.0005 0.0015 i n)
Land Cl earance (Di ametri cal ) . . . 0.635 1.016 mm
(0.025 0.040 i n)
Pi ston Length . . . . . . . . . . . . . . 86.360 mm (3.40 i n)
Pi ston Ri ng Groove Depth
Nos. 1 and 2 . . . . . . . . . . . . . . . . 4.572 4.826 mm
(0.180 0.190 i n)
No. 3 . . . . . . . . . . . . . . . . . . . . . . 3.810 4.064 mm
(0.150 0.160 i n)
Wei ght . . . . . . . . . . . . . . . . . . 592.6 596.6 grams
(20.90 21.04 oz)
Piston Pins
Cl earance
I n Pi ston . . . . . . . . . . . . . . . 0.00635 0.01905 mm
(0.00025 0.00075 i n)
I n Rod (I nterference) . . . . . . . . 0.0178 0.0356 mm
(0.0007 0.0014 i n)
Di ameter . . . . . . . . . . . . . . . . . 24.996 25.001 mm
(0.9841 0.9843 i n)
End Pl ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . NONE
Length . . . . . . . . . . . . . . . . . . 75.946 76.454 mm
(2.990 3.010 i n)
Piston Rings
Ri ng Gap
Compressi on Ri ngs . . . . . . . . . . . 0.254 0.508 mm
(0.010 0.020 i n)
Oi l Control (Steel Rai l s) . . . . . . . 0.254 1.270 mm
(0.010 0.050 i n)
Ri ng Si de Cl earance
Compressi on Ri ngs . . . . . . . . . . . 0.038 0.076 mm
(0.0015 0.0030 i n)
Oi l Ri ng (Steel Rai l s) . . . . . . . . . . . 0.06 0.21 mm
(0.002 0.008 i n)
Ri ng Wi dth
Compressi on Ri ngs . . . . . . . . . . . 1.971 1.989 mm
(0.0776 0.0783 i n)
Oi l Ri ng (Steel Rai l s) . . . . . . . . . 3.848 3.975 mm
(0.1515 0.1565 i n)
Valves
Face Angl e . . . . . . . . . . . . . . . . . . . 43.25 43.75
Head Di ameter
I ntake . . . . . . . . . . . . . . . . . . . 48.666 mm (1.916 i n)
Exhaust . . . . . . . . . . . . . . . . . 41.250 mm (1.624 i n)
Length (Overal l )
I ntake . . . . . . . . . . . . . . . . . . . 124.28 125.92 mm
(4.893 4.918 i n)
Exhaust . . . . . . . . . . . . . . . . . 124.64 125.27 mm
(4.907 4.932 i n)
Length (Overal l )
I ntake . . . . . . . . . . . . . . . . . . . 124.28 125.92 mm
(4.893 4.918 i n)
Exhaust . . . . . . . . . . . . . . . . . 124.64 125.27 mm
(4.907 4.932 i n)
Li ft (Zero Lash) . . . . . . . . . . . . 10.973 mm (0.432 i n)
Stem Di ameter . . . . . . . . . . . . . . 7.899 7.925 mm
(0.311 0.312 i n)
Stem-to-Gui de Cl earance . . . . 0.0254 0.0762 mm
(0.001 0.003 i n)
Max Al l owabl e (Rocki ng Method) . . . . . . 0.4318 mm
(0.017 i n)
Gui de Bore Di ameter (Std) . . . . . 7.950 7.976 mm
(0.313 0.314 i n)
9 - 84 5. 2L ENGINE ZG
SPECIFICATIONS (Continued)
Valve Springs
Free Length (Approx.) . . . . . . . 49.962 mm (1.967 i n)
Spri ng Tensi on (Val ve
Cl osed) . @ 41.66 mm = 378 N (@ 1.64 i n = 85 l bs)
Spri ng Tensi on (Val ve
Open) . @ 30.89 mm = 890 N (@ 1.212 i n = 200 l bs)
Number of Coi l s . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
I nstal l ed Hei ght (Spri ng Seat
o Retai ner) . . . . . . . . . . . . . . . 41.66 mm (1.64 i n)
Wi re Di ameter . . . . . . . . . . . . . . 4.50 mm (0.177 i n)
Valve Timing
Exhaust Val ve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cl oses (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Opens (BBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
I ntake Val ve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cl oses (ABC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Opens (BTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION
CRANKSHAFT JOURNALS
(UNDERSIZE) 0.0254 mm (0.001
in.)
R or M
M-2-3 etc. (indicating no. 2 and 3
main bearing journal)
and/or
R-1-4 etc. (indicating no. 1 and 4
connecting rod journal)
Milled flat on no. 8 crankshaft
counterweight.
HYDRAULIC TAPPETS
(OVERSIZE) 0.2032 mm (0.008 in.)
Diamond-shaped stamp top pad -
front of engine and flat ground on
outside surface of each O/S tappet
bore.
VALVE STEMS (OVERSIZE) 0.127
mm (0.005 in.)
X Milled pad adjacent to two tapped
holes (3/8 in.) on each end of
cylinder head.
ZG 5. 2L ENGINE 9 - 85
SPECIFICATIONS (Continued)
TORQUE
9 - 86 5. 2L ENGINE ZG
SPECIFICATIONS (Continued)
SPECIAL TOOLS
5. 9L ENGINE
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487A
Valve Spring Compressor MD-998772A
Adapter 6633
Adapter 6716A
Valve Guide Sleeve C-3973
Dial Indicator C-3339
Puller C-3688
ZG 5. 2L ENGINE 9 - 87
Front Oil Seal Installer 6635
Cam Bearing Remover/Installer C-3132A
Camshaft Holder C-3509
Distributor Bushing Puller C-3052
Distributor Bushing Driver/BurnisherC-3053
Piston Ring Compressor C-385
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
9 - 88 5. 2L ENGINE ZG
SPECIAL TOOLS (Continued)
5.9L ENGINE
INDEX
page page
GENERAL INFORMATION
OIL PUMP PRESSURE . . . . . . . . . . . . . . . . . . . 89
PISTON AND CONNECTING ROD ASSEMBLY . 89
DESCRIPTION AND OPERATION
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . 92
ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . 89
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . 90
SERVICE PROCEDURES
CRANKSHAFT SERVICE . . . . . . . . . . . . . . . . . 95
FITTING CONNECTING ROD BEARINGS . . . . . 94
FITTING CRANKSHAFT MAIN BEARINGS . . . . 94
FITTING PISTON RINGS . . . . . . . . . . . . . . . . . 93
FITTING PISTONS . . . . . . . . . . . . . . . . . . . . . . 93
MEASURING TIMING CHAIN STRETCH . . . . . . 92
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 92
REMOVAL AND INSTALLATION
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . 103
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 102
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . 104
CRANKSHAFT REAR OIL SEALS . . . . . . . . . . 109
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 107
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . 97
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 98
DISTRIBUTOR DRIVE SHAFT BUSHING . . . . 104
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 97
ENGINE CORE OIL AND CAMSHAFT PLUGS . 110
ENGINE MOUNTSFRONT . . . . . . . . . . . . . . . 95
ENGINE MOUNTSREAR . . . . . . . . . . . . . . . . 96
FRONT CRANKSHAFT OIL SEAL . . . . . . . . . . 108
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . 100
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
PISTON AND CONNECTING ROD
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 106
ROCKER ARMS AND PUSH RODS . . . . . . . . . 98
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . 101
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . 102
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE . . . . . . . . . . . . 98
VALVES AND VALVE SPRINGS . . . . . . . . . . . . 99
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . 100
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . 113
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . 111
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 111
CLEANING AND INSPECTION
CRANKSHAFT JOURNALS . . . . . . . . . . . . . . . 114
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . 116
CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . 114
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
PISTON AND CONNECTING ROD
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 114
SPECIFICATIONS
5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 117
SPECIAL TOOLS
5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 120
GENERAL INFORMATION
OIL PUMP PRESSURE
The MI NI MUM oi l pump pressure i s 41.4 kPa (6
psi ) at curb i dl e. The MAXI MUM oi l pump pressure
i s 207-552 kPa (30-80 psi ) at 3,000 RPM or more.
CAUTION: If oil pressure is ZERO at curb idle, DO
NOT run engine.
PISTON AND CONNECTING ROD ASSEMBLY
The pi stons are el l i pti cal l y turned so that the
di ameter at the pi n boss i s l ess than i ts di ameter
across the thrust face. Thi s al l ows for expansi on
under normal operati ng condi ti ons. Under operati ng
temperatures, expansi on forces the pi n bosses away
from each other, causi ng the pi ston to assume a more
nearl y round shape.
Al l pi stons are machi ned to the same wei ght,
regardl ess of si ze, to mai ntai n pi ston bal ance.
The pi ston pi n rotates i n the pi ston onl y and i s
retai ned by the press i nterference fi t of the pi ston
pi n i n the connecti ng rod.
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION
The 5.9 Li ter (360 CI D) ei ght-cyl i nder engi ne i s a
V-Type l i ghtwei ght, si ngl e cam, overhead val ve
engi ne wi th hydraul i c rol l er tappets.
Engi ne Type . . . . . . . . . . . . . . . . . . . . . 90 V-8 OHV
Bore and Stroke . . 101.6 x 90.9 mm (4.00 x 3.58 i n.)
Di spl acement . . . . . . . . . . . . . . . . . . . 5.9L (360 c.i .)
Compressi on Rati o . . . . . . . . . . . . . . . . . . . . . . 9.1:1
Torque . . . . . . . . 448 Nm (330 ft. l bs.) @ 3,250 rpm
ZG 5. 9L ENGINE 9 - 89
Engi ne Type . . . . . . . . . . . . . . . . . . . . . 90 V-8 OHV
Fi ri ng Order . . . . . . . . . . . . . . . . . 18436572
Lubri cati on . . . Pressure Feed Ful l Fl ow Fi l trati on
Engi ne Oi l Capaci ty . . . . . . . 4.7L (5.0 Qts.) w/fi l ter
Cool i ng System . Li qui d Cool ed Forced Ci rcul ati on
Cool i ng Capaci ty . . . . . . . . . . . . . . 14.7L (15.5 Qts.)
Cyl i nder Bl ock . . . . . . . . . . . . . . . . . . . . . . Cast I ron
Cyl i nder Head . . . . . . . . . . . . . . . . . . . . . . Cast I ron
Combusti on Chambers . . . . . . . . . Wedge-Hi gh Swi rl
Val ve Shroudi ng
Camshaft . . . . . . . . . . . . . . . . . . . Nodul ar Cast I ron
Pi stons . . . . . . . . . . . . . . . . . . Cast Al umi num Al l oy
Connecti ng Rods . . . . . . . . . . . . . . . . . . Forged Steel
Thi s engi ne i s desi gned for unl eaded fuel .
Engi ne l ubri cati on system consi sts of a rotor type
oi l pump and a ful l fl ow oi l fi l ter.
The cyl i nders are numbered from front to rear; 1,
3, 5, 7 on the l eft bank and 2, 4, 6, 8 on the ri ght
bank. The fi ri ng order i s 1-8-4-3-6-5-7-2 (Fi g. 1).
The engi ne seri al number i s stamped i nto a
machi ned pad l ocated on the l eft, front corner of the
cyl i nder bl ock. When component part repl acement i s
necessary, use the engi ne type and seri al number for
reference (Fi g. 2).
LUBRICATION SYSTEM
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the rear mai n beari ng
cap. The pump draws oi l through the screen and
i nl et tube from the sump at the rear of the oi l pan.
The oi l i s dri ven between the dri ve and i dl er gears
and pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength on the ri ght si de of the
bl ock. The oi l then goes down to the No. 1 mai n bear-
i ng, back up to the l eft si de of the bl ock and i nto the
oi l gal l ery on the l eft si de of the engi ne.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s to the connecti ng rod journal s.
Each connecti ng rod beari ng has hal f a hol e i n i t, oi l
passes through the hol e when the rods rotate and the
hol e l i nes up, oi l i s then thrown off as the rod
rotates. Thi s oi l throw off l ubri cates the camshaft
l obes, di stri butor dri ve gear, cyl i nder wal l s, and pi s-
ton pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. The camshaft beari ngs
recei ve oi l from the mai n beari ng gal l eri es. The front
camshaft beari ng journal passes oi l through the cam-
shaft sprocket to the ti mi ng chai n. Oi l drai ns back to
the oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components.
The oi l then passes down through the push rod gui de
hol es, and the oi l drai n back passages i n the cyl i nder
head past the val ve tappet area, and returns to the
oi l pan.
Fig. 1 Firing Order
CLOCKWISE ROTATION 18436572 FRONT OF ENGINE
Fig. 2 Engine Identification Number
X M 5.9L T XXXX XXXXXXXX X = Last Digit of Model Year M = Plant -M Mound Road S Saltillo T Trenton K Toluca 5.9L = Engine Displacement T = Usage - T Truck XXXX = Month/Day XXXXXXXX = Serial Code - Last 8 Digits of VIN No.
9 - 90 5. 9L ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
F
i
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.
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L
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i
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ZG 5. 9L ENGINE 9 - 91
DESCRIPTION AND OPERATION (Continued)
ENGINE COMPONENTS
CYLINDER HEADS
The al l oy cast i ron cyl i nder heads (Fi g. 4) are hel d
i n pl ace by 10 bol ts. The spark pl ugs are l ocated i n
the peak of the wedge between the val ves.
The 5.9L cyl i nder head i s i denti fi ed by the foundry
mark CF.
PISTONS
The pi stons are el l i pti cal l y turned so that the
di ameter at the pi n boss i s l ess than i ts di ameter
across the thrust face. Thi s al l ows for expansi on
under normal operati ng condi ti ons. Under operati ng
temperatures, expansi on forces the pi n bosses away
from each other, causi ng the pi ston to assume a more
nearl y round shape.
Al l pi stons are machi ned to the same wei ght,
regardl ess of si ze, to mai ntai n pi ston bal ance.
The pi ston pi n rotates i n the pi ston onl y and i s
retai ned by the press i nterference fi t of the pi ston
pi n i n the connecti ng rod.
VALVES AND VALVE SPRINGS
The val ves are arranged i n-l i ne and i ncl i ned 18.
The rocker pi vot support and the val ve gui des are
cast i ntegral wi th the heads.
SERVICE PROCEDURES
VALVE TIMING
(1) Turn crankshaft unti l the No.6 exhaust val ve i s
cl osi ng and No.6 i ntake val ve i s openi ng.
(2) I nsert a 6.350 mm (1/4 i nch) spacer between
rocker arm pad and stem ti p of No.1 i ntake val ve.
Al l ow spri ng l oad to bl eed tappet down gi vi ng i n
effect a sol i d tappet.
(3) I nstal l a di al i ndi cator so pl unger contacts
val ve spri ng retai ner as nearl y perpendi cul ar as pos-
si bl e. Zero the i ndi cator.
(4) Rotate the crankshaft cl ockwi se (normal run-
ni ng di recti on) unti l the val ve has l i fted 0.863 mm
(0.034 i nch). The ti mi ng of the crankshaft shoul d
now read from 10 before top dead center to 2 after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.
I f readi ng i s not wi thi n speci fi ed l i mi ts:
Check sprocket i ndex marks.
I nspect ti mi ng chai n for wear.
Check accuracy of DC mark on ti mi ng i ndi cator.
MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing
Chain Cover in Removal and Installation Section.
(1) Pl ace a scal e next to the ti mi ng chai n so that
any movement of the chai n may be measured.
(2) Pl ace a torque wrench and socket over cam-
shaft sprocket attachi ng bol t. Appl y torque i n the
di recti on of crankshaft rotati on to take up sl ack; 41
Nm (30 ft. l bs.) torque wi th cyl i nder head i nstal l ed
or 20 Nm (15 ft. l bs.) torque wi th cyl i nder head
removed. Wi th a torque appl i ed to the camshaft
sprocket bol t, crankshaft shoul d not be permi tted to
move. I t may be necessary to bl ock the crankshaft to
prevent rotati on.
(3) Hol d a scal e wi th di mensi onal readi ng even
wi th the edge of a chai n l i nk. Wi th cyl i nder heads
i nstal l ed, appl y 14 Nm (30 ft. l bs.) torque i n the
reverse di recti on. Wi th the cyl i nder heads removed,
appl y 20 Nm (15 ft. l bs.) torque i n the reverse di rec-
ti on. Note the amount of chai n movement (Fi g. 5).
(4) I nstal l a new ti mi ng chai n, i f i ts movement
exceeds 3.175 mm (1/8 i nch).
(5) I f chai n i s not sati sfactory, remove camshaft
sprocket attachi ng bol t and remove ti mi ng chai n wi th
crankshaft and camshaft sprockets.
(6) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on exact
Fig. 4 Cylinder Head Assembly
EXHAUST VALVE SPARK PLUGS EXHAUST VALVES SPARK PLUGS EXHAUST VALVE INTAKE VALVES INTAKE VALVES
Fig. 5 Measuring Timing Chain Wear and Stretch
TORQUE WRENCH
3.175 MM
(0.125 IN.)
9 - 92 5. 9L ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
i magi nary center l i ne through both camshaft and
crankshaft bores.
(7) Pl ace ti mi ng chai n around both sprockets.
(8) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(9) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed).
(10) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 6).
(11) I nstal l the camshaft bol t. Ti ghten the bol t to
47 Nm (35 ft. l bs.) torque.
(12) Check camshaft end pl ay. The end pl ay shoul d
be 0.051-0.152 mm (0.002-0.006 i nch) wi th a new
thrust pl ate and up to 0.254 mm (0.010 i nch) wi th a
used thrust pl ate. I f not wi thi n these l i mi ts i nstal l a
new thrust pl ate.
FITTING PISTONS
Pi ston and cyl i nder wal l must be cl ean and dry.
Speci fi ed cl earance between the pi ston and the cyl i n-
der wal l i s 0.013-0.038 mm (0.0005-0.0015 i nch) at
21C (70F).
Pi ston di ameter shoul d be measured at the top of
ski rt, 90 to pi ston pi n axi s. Cyl i nder bores shoul d be
measured hal fway down the cyl i nder bore and trans-
verse to the engi ne crankshaft center l i ne.
Pi stons and cyl i nder bores shoul d be measured at
normal room temperature, 21C (70F).
Check the pi stons for taper and el l i pti cal shape
before they are fi tted i nto the cyl i nder bore (Fi g. 7).
FITTING PISTON RINGS
(1) Measurement of end gaps:
(a) Measure pi ston ri ng gap 2 i nches from bot-
tom of cyl i nder bore. An i nverted pi ston can be
used to push the ri ngs down to ensure posi ti oni ng
ri ngs squarel y i n the cyl i nder bore before measur-
i ng.
(b) I nsert feel er gauge i n the gap. The top com-
pressi on ri ng gap shoul d be between 0.254-0.508
mm (0.010-0.020 i nch). The second compressi on
ri ng gap shoul d be between 0.508-0.762 mm (0.020-
0.030 i nch). The oi l ri ng gap shoul d be 0.254-1.270
mm (0.010-0.050 i nch).
(c) Ri ngs wi th i nsuffi ci ent end gap may be prop-
erl y fi l ed to the correct di mensi on. Ri ngs wi th
excess gaps shoul d not be used.
(2) I nstal l ri ngs and confi rm ri ng si de cl earance:
(a) I nstal l oi l ri ngs bei ng careful not to ni ck or
scratch the pi ston. I nstal l the oi l control ri ngs
accordi ng to i nstructi ons i n the package. I t i s not
necessary to use a tool to i nstal l the upper and
l ower rai l s. I nsert oi l rai l spacer fi rst, then si de
rai l s.
(b) I nstal l the second compressi on ri ngs usi ng
I nstal l ati on Tool C-4184. The compressi on ri ngs
must be i nstal l ed wi th the i denti fi cati on mark face
up (toward top of pi ston) and chamfer faci ng down.
An i denti fi cati on mark on the ri ng i s a dri l l poi nt,
a stamped l etter O, an oval depressi on or the
word TOP (Fi g. 8) (Fi g. 10).
(c) Usi ng a ri ng i nstal l er, i nstal l the top com-
pressi on ri ng wi th the chamfer faci ng up (Fi g. 9)
(Fi g. 10). An i denti fi cati on mark on the ri ng i s a
dri l l poi nt, a stamped l etter O, an oval depressi on
or the word TOP faci ng up.
(d) Measure si de cl earance between pi ston ri ng
and ri ng l and. Cl earance shoul d be 0.074-0.097 mm
Fig. 6 Alignment of Timing Marks
TIMING MARKS
Fig. 7 Piston Measurements
PISTON PIN BORE DIAME- TER 25.007 - 25.015 mm (.9845 - .9848 IN.)
ZG 5. 9L ENGINE 9 - 93
SERVICE PROCEDURES (Continued)
(0.0029-0.0038 i nch) for the compressi on ri ngs. The
steel rai l oi l ri ng shoul d be free i n groove, but
shoul d not exceed 0.246 mm (0.0097 i nch) si de
cl earance.
(e) Pi stons wi th i nsuffi ci ent or excessi ve si de
cl earance shoul d be repl aced.
FITTING CONNECTING ROD BEARINGS
Fi t al l rods on a bank unti l compl eted. DO NOT
al ternate from one bank to another, because connect-
i ng rods and pi stons are not i nterchangeabl e from
one bank to another.
The beari ng caps are not i nterchangeabl e and
shoul d be marked at removal to ensure correct
assembl y.
Each beari ng cap has a smal l V-groove across the
parti ng face. When i nstal l i ng the l ower beari ng shel l ,
make certai n that the V-groove i n the shel l i s i n l i ne
wi th the V-groove i n the cap. Thi s provi des l ubri ca-
ti on of the cyl i nder wal l i n the opposi te bank.
The beari ng shel l s must be i nstal l ed so that the
tangs are i n the machi ned grooves i n the rods and
caps.
Li mi ts of taper or out-of-round on any crankshaft
journal s shoul d be hel d to 0.025 mm (0.001 i nch).
Beari ngs are avai l abl e i n 0.025 mm (0.001 i nch),
0.051 mm (0.002 i nch), 0.076 mm (0.003 i nch), 0.254
mm (0.010 i nch) and 0.305 mm (0.012 i nch) under-
si ze. Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
NOT file the rods or bearing caps.
FITTING CRANKSHAFT MAIN BEARINGS
Beari ng caps are not i nterchangeabl e and shoul d
be marked at removal to ensure correct assembl y.
Upper and l ower beari ng hal ves are NOT i nter-
changeabl e. Lower mai n beari ng hal ves of No.2 and 4
are i nterchangeabl e.
Upper and l ower No.3 beari ng hal ves are fl anged
to carry the crankshaft thrust l oads. They are NOT
i nterchangeabl e wi th any other beari ng hal ves i n the
engi ne (Fi g. 12). Beari ng shel l s are avai l abl e i n stan-
dard and the fol l owi ng undersi zes: 0.25 mm (0.001
i nch), 0.051 mm (0.002 i nch), 0.076 mm (0.003 i nch),
0.254 mm (0.010 i nch) and 0.305 mm (0.012 i nch).
Never i nstal l an undersi ze beari ng that wi l l reduce
cl earance bel ow speci fi cati ons.
Fig. 8 Second Compression Ring
Identification(Typical)
SECOND COMPRESSION RING (BLACK CAST IRON) CHAMFER TWO DOTS
Fig. 9 Top Compression Ring Identification(Typical)
TOP COMPRESSION RING (GRAY IN COLOR) CHAMFER ONE DOT
Fig. 10 Compression Ring Chamfer
Location(Typical)
CHAMFER TOP COMPRESSION RING SECOND COMPRES- SION RING PISTON CHAMFER
Fig. 11 Proper Ring Installation
OIL RING SPACER GAP SECOND COM- PRESSION RING GAP OIL RING RAIL GAP (TOP) OIL RING RAIL GAP (BOTTOM) TOP COMPRES- SION RING GAP
9 - 94 5. 9L ENGINE ZG
SERVICE PROCEDURES (Continued)
CRANKSHAFT SERVICE
A crankshaft whi ch has undersi ze journal s wi l l be
stamped wi th 1/4 i nch l etters on the mi l l ed fl at on
the No.3 crankshaft counterwei ght (Fi g. 13).
FOR EXAMPLE: R2 stamped on the No.3 crank-
shaft counterwei ght i ndi cates that the No.2 rod jour-
nal i s 0.025 mm (0.001 i n) undersi ze. M4 i ndi cates
that the No.4 mai n journal i s 0.025 mm (0.001 i n)
undersi ze. R3 M2 i ndi cates that the No.3 rod journal
and the No.2 mai n journal are 0.025 mm (0.001 i n)
undersi ze.
When a crankshaft i s repl aced, al l mai n and con-
necti ng rod beari ngs shoul d be repl aced wi th new
beari ngs. Therefore, sel ecti ve fi tti ng of the beari ngs
i s not requi red when a crankshaft and beari ngs are
repl aced.
INSPECTION OF J OURNALS
The crankshaft connecti ng rod and mai n journal s
shoul d be checked for excessi ve wear, taper and scor-
i ng. The maxi mum taper or out-of-round on any
crankshaft journal i s 0.025 mm (0.001 i nch).
Journal gri ndi ng shoul d not exceed 0.305 mm
(0.012 i nch) under the standard journal di ameter. DO
NOT gri nd thrust faces of No.3 mai n beari ng. DO
NOT ni ck crank pi n or beari ng fi l l ets. After gri ndi ng,
remove rough edges from crankshaft oi l hol es and
cl ean out al l oi l passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.
REMOVAL AND INSTALLATION
ENGINE MOUNTSFRONT
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Posi ti on fan to assure cl earance for radi ator top
tank and hose.
CAUTION: DO NOT lift the engine by the intake
manifold.
(3) I nstal l engi ne l i fti ng fi xture.
(4) Rai se vehi cl e on hoi st.
(5) Remove the engi ne support i nsul ator thru-bol ts
and nuts (Fi g. 14) (Fi g. 15).
(6) Rai se engi ne SLI GHTLY. Remove the engi ne
support i nsul ator bol ts. Remove the engi ne support
i nsul ator assembl y.
(7) I f requi red, remove the si l l bracket assembl y.
INSTALLATION
(1) I f the si l l bracket assembl y was removed,
i nstal l the bracket to the si l l assembl y.
Fig. 12 Main Bearing Identification
UPPER
LOWER
Fig. 13 Location of Crankshaft Identification
Undersize Journal
Identification Stamp
0.025 mm (0.001 inch) (Rod) 0.025 mm (0.001 inch) (Main)
Fig. 14 Front Engine MountRight Side
SILL BRACKET ASSEMBLY ENGINE SUP- PORT INSULA- TOR ASM. THROUGH-BOLT RIGHT SIDE
ZG 5. 9L ENGINE 9 - 95
SERVICE PROCEDURES (Continued)
(a) RI GHT SI DEI nstal l the si l l bracket assem-
bl y onto the si l l assembl y (Fi g. 14). I nstal l and
ti ghten the bol ts to 65 Nm (48 ft. l bs.) torque.
(b) LEFT SI DEI nstal l the si l l bracket assem-
bl y onto the si l l assembl y (Fi g. 15). I nstal l and
ti ghten the 2 top bol ts to 65 Nm (48 ft. l bs.)
torque. I nstal l and ti ghten the 2 si de bol ts to 95
Nm (70 ft. l bs.) torque. I nstal l and ti ghten the 2
bottom bol ts to 121 Nm (89 ft. l bs.) torque.
(2) Wi th the engi ne rai sed SLI GHTLY, posi ti on
engi ne support i nsul ator assembl y onto the engi ne
bl ock (Fi g. 14) (Fi g. 15). I nstal l bol ts and ti ghten to
88 Nm (65 ft. l bs.) torque.
(3) Lower engi ne wi th l i fti ng fi xture whi l e al i gni ng
engi ne support i nsul ator assembl y i nto si l l bracket
assembl y.
(4) I nstal l the thru-bol t and nut. Ti ghten the
RI GHT SI DE nut to 81 Nm (60 ft. l bs.) torque.
Ti ghten the LEFT SI DE nut to 81 Nm (60 ft. l bs.)
torque.
(5) Lower the vehi cl e.
(6) Remove l i fti ng fi xture.
(7) Connect the negati ve cabl e to the battery.
ENGINE MOUNTSREAR
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the bol ts hol di ng the mount assy. to
the crossmember.
(4) Rai se the transmi ssi on and engi ne SLI GHTLY.
(5) Remove engi ne mount bracket thru-bol t and
nut (Fi g. 16).
(6) Remove the rear mount assy.
(7) I f necessary, remove the bol ts hol di ng the rear
mount bracket to the transmi ssi on. Remove the
bracket from the exhaust pi pe hanger. Remove the
bracket.
INSTALLATION
(1) Posi ti on the rear mount bracket onto the
exhaust hanger (i f previ ousl y removed). Posi ti on the
rear mount bracket assembl y onto the transmi ssi on
and i nstal l the bol ts. Ti ghten the bol ts to 46 Nm (34
ft. l bs.).
(2) Posi ti on the mount i nto the mount bracket and
i nstal l the thru-bol t and nut. DO NOT ti ghten the
bol t at thi s ti me.
(3) I nstal l the engi ne mount bracket assembl y to
the adaptor. I nstal l the bol ts and ti ghten to 75 Nm
(55 ft. l bs.) torque.
(4) Lower the transmi ssi on unti l the mount fasten-
i ng studs are i n posi ti on i n the crossmember.
(5) Remove the transmi ssi on support.
(6) I nstal l the mount fasteni ng nuts and ti ghten
the nuts to 54 Nm (40 ft. l bs.) torque.
(7) Ti ghten the thru-bol t nut to 65 Nm (48 ft. l bs.)
torque.
(8) Lower the vehi cl e.
(9) Connect the negati ve cabl e to the battery.
Fig. 15 Front Engine MountLeft Side
ENGINE SUPPORT INSULATOR ASM. TOP BOLTS BOTTOM BOLTS SIDE BOLTS SILL BRACKET ASSEMBLY THROUGH-BOLT LEFT SIDE
Fig. 16 Engine Rear Support Assembly
TRANS. ASSY.
BRACKET
CROSSMEMBER
9 - 96 5. 9L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
ENGINE ASSEMBLY
REMOVAL
(1) Scri be hood hi nge outl i nes on hood and remove
the hood.
(2) Remove the battery.
(3) Drai n cool i ng system.
(4) Remove the ai r cl eaner and tube.
(5) Set fan shroud asi de.
(6) Remove radi ator and heater hoses. Remove the
radi ator (refer to Group 7, Cool i ng System).
(7) Remove the vacuum l i nes.
(8) Remove the di stri butor cap and wi ri ng.
(9) Di sconnect the accel erator l i nkage.
(10) Perform the Fuel System Pressure Rel ease
procedure (refer to Group 14, Fuel System).
(11) Remove throttl e body.
(12) Remove the starter wi res.
(13) Remove the oi l pressure wi re.
(14) Di scharge the ai r condi ti oni ng system, i f
equi pped (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng for servi ce procedures).
(15) Remove ai r condi ti oni ng hoses.
(16) Di sconnect the power steeri ng hoses, i f
equi pped.
(17) Remove starter motor (refer to Group 8B, Bat-
tery/Starter Servi ce).
(18) Remove the generator (refer to Group 8C,
Generator Servi ce).
(19) Rai se and support the vehi cl e on a hoi st.
(20) Di sconnect exhaust pi pe at mani fol d.
(21) Support automati c transmi ssi on wi th a trans-
mi ssi on stand. Thi s wi l l assure that the torque con-
verter wi l l remai n i n proper posi ti on i n the
transmi ssi on housi ng.
(22) Remove bel l housi ng bol ts and i nspecti on
pl ate. Attach C-cl amp on front bottom of transmi s-
si on torque converter housi ng to prevent torque con-
verter from comi ng out.
(23) Remove torque converter dri ve pl ate bol ts
from torque converter dri ve pl ate. Mark converter
and dri ve pl ate to ai d i n assembl y.
(24) Di sconnect the engi ne from the torque con-
verter dri ve pl ate.
CAUTION: DO NOT lift the engine by the intake
manifold.
(25) I nstal l an engi ne l i fti ng fi xture.
(26) Remove the engi ne front mount thru-bol ts.
(27) Lower the vehi cl e.
(28) Remove engi ne from engi ne compartment.
(29) I nstal l on engi ne repai r stand.
INSTALLATION
(1) Remove engi ne from the repai r stand and posi -
ti on i n the engi ne compartment.
(2) I nstal l engi ne support fi xture.
(3) Rai se and support the vehi cl e on a hoi st.
(4) Posi ti on the torque converter and dri ve pl ate.
I nstal l torque converter dri ve pl ate bol ts. Ti ghten the
bol ts to 31 Nm (270 i n. l bs.) torque.
(5) I nstal l the engi ne front mount thru-bol ts.
(6) I nstal l bel l housi ng bol ts. Ti ghten the bol ts to
41 Nm (30 ft. l bs.) torque.
(7) Remove C-cl amp and i nstal l i nspecti on pl ate.
(8) Remove stand from transmi ssi on.
(9) I nstal l exhaust pi pe to mani fol d.
(10) Lower the vehi cl e.
(11) Remove engi ne l i fti ng fi xture.
(12) I nstal l the generator (refer to Group 8C, Gen-
erator Servi ce).
(13) I nstal l starter motor (refer to Group 8B, Bat-
tery/Starter Servi ce).
(14) I nstal l power steeri ng hoses, i f equi pped.
(15) I nstal l ai r condi ti oni ng hoses.
(16) Charge the ai r condi ti oner, i f equi pped (refer
to Group 24, Heater and Ai r Condi ti oni ng for servi ce
procedures).
(17) Usi ng a new gasket, i nstal l throttl e body.
Ti ghten the throttl e body bol ts to 23 Nm (200 i n.
l bs.) torque.
(18) Connect the accel erator l i nkage.
(19) Connect the starter wi res.
(20) Connect the oi l pressure wi re.
(21) I nstal l the di stri butor cap and wi ri ng.
(22) I nstal l vacuum l i nes.
(23) I nstal l radi ator, radi ator hoses and heater
hoses (refer to Group 7, Cool i ng System).
(24) I nstal l fan shroud i n posi ti on.
(25) I nstal l the battery
(26) Fi l l cool i ng system (refer to Group 7, Cool i ng
System for the proper procedure).
(27) I nstal l the ai r cl eaner.
(28) Warm engi ne and adjust.
(29) I nstal l hood and l i ne up.
(30) Road test vehi cl e.
CYLINDER HEAD COVER
A steel backed si l i con gasket i s used wi th the cyl -
i nder head cover (Fi g. 17). Thi s gasket can be used
agai n.
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Di sconnect cl osed venti l ati on system and evap-
orati on control system from cyl i nder head cover.
(3) Remove cyl i nder head cover and gasket. The
gasket may be used agai n.
INSTALLATION
(1) Cl ean cyl i nder head cover gasket surface.
(2) Cl ean head rai l , i f necessary.
ZG 5. 9L ENGINE 9 - 97
REMOVAL AND INSTALLATION (Continued)
(3) I nspect cover for di storti on and strai ghten, i f
necessary.
(4) Check the gasket for use i n head cover i nstal -
l ati on. I f damaged, use a new gasket.
(5) Posi ti on the cyl i nder head cover onto the gas-
ket. Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
(6) I nstal l cl osed crankcase venti l ati on system and
evaporati on control system.
(7) Connect the negati ve cabl e to the battery.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Di sconnect spark pl ug wi res by pul l i ng on the
boot strai ght out i n l i ne wi th pl ug.
(2) Remove cyl i nder head cover and gasket.
(3) Remove the rocker arm bol ts and pi vots (Fi g.
18). Pl ace them on a bench i n the same order as
removed.
(4) Remove the push rods and pl ace them on a
bench i n the same order as removed.
INSTALLATION
(1) Rotate the crankshaft unti l the V8 mark l i nes
up wi th the TDC mark on the ti mi ng chai n case
cover. Thi s mark i s l ocated 147 ATDC from the No.1
fi ri ng posi ti on.
(2) I nstal l the push rods i n the same order as
removed.
(3) I nstal l rocker arm and pi vot assembl i es i n the
same order as removed. Ti ghten the rocker arm bol ts
to 28 Nm (21 ft. l bs.) torque.
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) I nstal l cyl i nder head cover.
(5) Connect spark pl ug wi res.
VALVE SPRING AND STEM SEAL REPLACEMENT-
IN VEHICLE
(1) Set engi ne basi c ti mi ng to Top Dead Center
(TDC).
(2) Remove the ai r cl eaner.
(3) Remove cyl i nder head covers and spark pl ugs.
(4) Remove coi l wi re from di stri butor and secure to
good ground to prevent engi ne from starti ng.
(5) Usi ng sui tabl e socket and fl ex handl e at crank-
shaft retai ni ng bol t, turn engi ne so the No.1 pi ston i s
at TDC on the compressi on stroke.
(6) Remove rocker arms.
(7) Wi th ai r hose attached to an adapter i nstal l ed
i n No.1 spark pl ug hol e, appl y 620-689 kPa (90-100
psi ) ai r pressure.
(8) Usi ng Val ve Spri ng Compressor Tool
MD-998772A wi th adaptor 6633, compress val ve
spri ng and remove retai ner val ve l ocks and val ve
spri ng.
(9) I nstal l seal s on the exhaust val ve stem and
posi ti on down agai nst val ve gui des.
(10) The i ntake val ve stem seal s shoul d be pushed
fi rml y and squarel y over the val ve gui de usi ng the
val ve stem as a gui de. DO NOT force seal agai nst top
of gui de. When i nstal l i ng the val ve retai ner l ocks,
compress the spri ng onl y enough to i nstal l the l ocks.
(11) Fol l ow the same procedure on the remai ni ng 7
cyl i nders usi ng the fi ri ng sequence 1-8-4-3-6-5-7-2.
Make sure pi ston i n cyl i nder i s at TDC on the val ve
spri ng that i s bei ng removed.
(12) Remove adapter from the No.1 spark pl ug
hol e.
(13) I nstal l rocker arms.
(14) I nstal l covers and coi l wi re to di stri butor.
(15) I nstal l ai r cl eaner.
(16) Road test vehi cl e.
CYLINDER HEAD
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Drai n cool i ng system (refer to Group 7, Cool i ng
System for the proper procedures).
(3) Remove the generator.
(4) Remove cl osed crankcase venti l ati on system.
(5) Di sconnect the evaporati on control system.
(6) Remove the ai r cl eaner.
Fig. 17 Cylinder Head Cover Gasket
CYLINDER HEAD COVER GASKET
Fig. 18 Rocker Arms
ROCKER ARMS CYLINDERHEAD
9 - 98 5. 9L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(7) Perform the Fuel System Pressure Rel ease pro-
cedure (refer to Group 14, Fuel System). Di sconnect
the fuel l i nes.
(8) Di sconnect accel erator l i nkage and i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(9) Remove the return spri ng.
(10) Remove di stri butor cap and wi res.
(11) Di sconnect the coi l wi res.
(12) Di sconnect heat i ndi cator sendi ng uni t wi re.
(13) Di sconnect heater hoses and bypass hose.
(14) Remove cyl i nder head covers and gaskets.
(15) Remove i ntake mani fol d and throttl e body as
an assembl y. Di scard the fl ange si de gaskets and the
front and rear cross-over gaskets.
(16) Remove exhaust mani fol ds.
(17) Remove rocker arm assembl i es and push rods.
I denti fy to ensure i nstal l ati on i n ori gi nal l ocati ons.
(18) Remove the head bol ts from each cyl i nder
head and remove cyl i nder heads. Di scard the cyl i n-
der head gasket.
(19) Remove spark pl ugs.
INSTALLATION
(1) Posi ti on the new cyl i nder head gaskets onto
the cyl i nder bl ock.
(2) Posi ti on the cyl i nder heads onto head gaskets
and cyl i nder bl ock.
(3) Starti ng at top center, ti ghten al l cyl i nder head
bol ts, i n sequence, to 68 Nm (50 ft. l bs.) torque (Fi g.
19). Repeat procedure, ti ghten al l cyl i nder head bol ts
to 143 Nm (105 ft. l bs.) torque. Repeat procedure to
confi rm that al l bol ts are at 143 Nm (105 ft. l bs.)
torque.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) I nstal l push rods and rocker arm assembl i es i n
thei r ori gi nal posi ti on. Ti ghten the bol ts to 28 Nm
(21 ft. l bs.) torque.
(5) I nstal l the i ntake mani fol d and throttl e body
assembl y (refer to Group 11, Exhaust System and
I ntake Mani fol d).
(6) I nstal l exhaust mani fol ds. Ti ghten the bol ts
and nuts to 34 Nm (25 ft. l bs.) torque.
(7) Adjust spark pl ugs to speci fi cati ons (refer to
Group 8D, I gni ti on System). I nstal l the pl ugs and
ti ghten to 41 Nm (30 ft. l bs.) torque.
(8) I nstal l coi l wi res.
(9) Connect heat i ndi cator sendi ng uni t wi re.
(10) Connect the heater hoses and bypass hose.
(11) I nstal l di stri butor cap and wi res.
(12) Hook up the return spri ng.
(13) Connect the accel erator l i nkage and i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(14) I nstal l the fuel l i nes.
(15) I nstal l the generator and dri ve bel t. Ti ghten
generator mounti ng bol t to 41 Nm (30 ft. l bs.)
torque. Ti ghten the adjusti ng strap bol t to 23 Nm
(200 i n. l bs.) torque. Refer to Group 7, Cool i ng Sys-
tem for adjusti ng the bel t tensi on.
(16) I nstal l the i ntake mani fol d-to-generator
bracket support rod. Ti ghten the bol ts.
(17) Pl ace the cyl i nder head cover gaskets i n posi -
ti on and i nstal l cyl i nder head covers. Ti ghten the
bol ts to 11 Nm (95 i n. l bs.) torque.
(18) I nstal l cl osed crankcase venti l ati on system.
(19) Connect the evaporati on control system.
(20) I nstal l the ai r cl eaner.
(21) Fi l l cool i ng system (refer to Group 7, Cool i ng
System for proper procedure).
(22) Connect the negati ve cabl e to the battery.
VALVES AND VALVE SPRINGS
REMOVAL
(1) Remove the cyl i nder head.
(2) Compress val ve spri ngs usi ng Val ve Spri ng
Compressor Tool MD- 998772A.
(3) Remove val ve retai ni ng l ocks, val ve spri ng
retai ners, val ve stem seal s and val ve spri ngs.
(4) Before removi ng val ves, remove any burrs from
val ve stem l ock grooves to prevent damage to the
val ve gui des. I denti fy val ves to ensure i nstal l ati on i n
ori gi nal l ocati on.
INSTALLATION
(1) Cl ean val ves thoroughl y. Di scard burned,
warped and cracked val ves.
(2) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(3) Measure val ve stems for wear. I f wear exceeds
0.051 mm (0.002 i nch), repl ace the val ve.
Fig. 19 Cylinder Head Bolt Tightening Sequence
FOUNDRY MARK NH
ZG 5. 9L ENGINE 9 - 99
REMOVAL AND INSTALLATION (Continued)
(4) Coat val ve stems wi th l ubri cati on oi l and i nsert
them i n cyl i nder head.
(5) I f val ves or seats are reground, check val ve
stem hei ght. I f val ve i s too l ong, repl ace cyl i nder
head.
(6) I nstal l new seal s on al l val ve gui des. I nstal l
val ve spri ngs and val ve retai ners.
(7) Compress val ve spri ngs wi th Val ve Spri ng
Compressor Tool MD-998772A, i nstal l l ocks and
rel ease tool . I f val ves and/or seats are ground, mea-
sure the i nstal l ed hei ght of spri ngs. Make sure the
measurement i s taken from bottom of spri ng seat i n
cyl i nder head to the bottom surface of spri ng
retai ner. I f spacers are i nstal l ed, measure from the
top of spacer. I f hei ght i s greater than 42.86 mm
(1-11/16 i nches), i nstal l a 1.587 mm (1/16 i nch)
spacer i n head counterbore. Thi s shoul d bri ng spri ng
hei ght back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 i nch).
HYDRAULIC TAPPETS
REMOVAL
(1) Remove the ai r cl eaner.
(2) Remove cyl i nder head cover, rocker assembl y
and push rods. I denti fy push rods to ensure i nstal l a-
ti on i n ori gi nal l ocati on.
(3) Remove i ntake mani fol d, yoke retai ner and
al i gni ng yokes.
(4) Sl i de Hydraul i c Tappet Remover/I nstal l er Tool
C-4129-A through openi ng i n cyl i nder head and seat
tool fi rml y i n the head of tappet.
(5) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed, i denti fy tappets to
ensure i nstal l ati on i n ori gi nal l ocati on.
INSTALLATION
(1) I f the tappet or bore i n cyl i nder bl ock i s
scored, scuffed, or shows si gns of sti cki ng, ream the
bore to next oversi ze. Repl ace wi th oversi ze tappet.
(2) Lubri cate tappets.
(3) I nstal l tappets and push rods i n thei r ori gi nal
posi ti ons. Ensure that the oi l feed hol e i n the si de of
the tappet body faces up (away from the crankshaft).
(4) I nstal l al i gni ng yokes wi th ARROW toward
camshaft.
(5) I nstal l yoke retai ner. Ti ghten the bol ts to 23
Nm (200 i n. l bs.) torque. I nstal l i ntake mani fol d.
(6) I nstal l push rods i n ori gi nal posi ti ons.
(7) I nstal l rocker arm.
(8) I nstal l cyl i nder head cover.
(9) Start and operate engi ne. Warm up to normal
operati ng temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Remove fan shroud retai ner bol ts and set
shroud back over engi ne.
(3) Remove the cool i ng system fan.
(4) Remove the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(5) Remove the vi brati on damper pul l ey.
(6) Remove vi brati on damper bol t and washer from
end of crankshaft.
(7) I nstal l bar and screw from Pul l er Tool Set
C-3688. I nstal l 2 bol ts wi th washers through the
pul l er tool and i nto the vi brati on damper (Fi g. 20).
(8) Pul l vi brati on damper off of the crankshaft.
INSTALLATION
(1) Posi ti on the vi brati on damper onto the crank-
shaft.
(2) Pl ace i nstal l i ng tool , part of Pul l er Tool Set
C-3688 i n posi ti on and press the vi brati on damper
onto the crankshaft (Fi g. 21).
(3) I nstal l the crankshaft bol t and washer. Ti ghten
the bol t to 183 Nm (135 ft. l bs.) torque.
Fig. 20 Vibration Damper Assembly
SPECIAL TOOL C-3688
Fig. 21 Installing Vibration Damper
SPECIAL TOOL C-3688
9 - 100 5. 9L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l the crankshaft pul l ey. Ti ghten the pul -
l ey bol ts to 23 Nm (200 i n. l bs.) torque.
(5) I nstal l the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(6) I nstal l the cool i ng system fan. Ti ghten the
bol ts to 23 Nm (17 ft. l bs.) torque.
(7) Posi ti on the fan shroud and i nstal l the bol ts.
Ti ghten the retai ner bol ts to 11 Nm (95 i n. l bs.)
torque.
(8) Connect the negati ve cabl e to the battery.
TIMING CHAIN COVER
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Drai n cool i ng system (refer to Group 7, Cool i ng
System).
(3) Remove the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(4) Remove water pump (refer to Group 7, Cool i ng
System).
(5) Remove power steeri ng pump (refer to Group
19, Steeri ng).
(6) Remove vi brati on damper.
(7) Loosen oi l pan bol ts and remove the front bol t
at each si de.
(8) Remove the cover bol ts.
(9) Remove chai n case cover and gasket usi ng
extreme cauti on to avoi d damagi ng oi l pan gasket.
(10) Pl ace a sui tabl e tool behi nd the l i ps of the oi l
seal to pry the oi l seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fi g. 22).
INSTALLATION
(1) Usi ng a new cover gasket, careful l y i nstal l
chai n case cover to avoi d damagi ng oi l pan gasket.
Use a smal l amount of Mopar Si l i cone Rubber Adhe-
si ve Seal ant, or equi val ent, at the joi nt between ti m-
i ng chai n cover gasket and the oi l pan gasket. Fi nger
ti ghten the ti mi ng chai n cover bol ts at thi s ti me.
(2) Pl ace the smal l er di ameter of the oi l seal over
Front Oi l Seal I nstal l ati on Tool 6635 (Fi g. 23). Seat
the oi l seal i n the groove of the tool .
(3) Posi ti on the seal and tool onto the crankshaft
(Fi g. 24).
(4) Ti ghten the 4 l ower chai n case cover bol ts to
13Nm (10 ft.l bs.) to prevent the cover from ti ppi ng
duri ng seal i nstal l ati on.
(5) Usi ng the vi brati on damper bol t, ti ghten the
bol t to draw the seal i nto posi ti on on the crankshaft
(Fi g. 25).
(6) Loosen the 4 bol ts ti ghtened i n step 4 to al l ow
real i gnment of front cover assembl y.
(7) Ti ghten chai n case cover bol ts to 41 Nm (30 ft.
l bs.) torque. Ti ghten oi l pan bol ts to 24 Nm (215 i n.
l bs.) torque.
(8) Remove the vi brati on damper bol t and seal
i nstal l ati on tool .
(9) I nstal l vi brati on damper.
Fig. 22 Removal of Front Crankshaft Oil Seal
Fig. 23 Placing Oil Seal on InstallationTool 6635
CRANKSHAFT FRONT OIL SEAL INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 24 Position Tool and Seal onto Crankshaft
SPECIAL TOOL 6635 OIL SEAL TIMING CHAIN COVER
ZG 5. 9L ENGINE 9 - 101
REMOVAL AND INSTALLATION (Continued)
(10) I nstal l water pump and housi ng assembl y
usi ng new gaskets (refer to Group 7, Cool i ng Sys-
tem). Ti ghten bol ts to 41 Nm (30 ft. l bs.) torque.
(11) I nstal l power steeri ng pump (refer to Group
19, Steeri ng).
(12) I nstal l the serpenti ne bel t (refer to Group 7,
Cool i ng System).
(13) I nstal l the cool i ng system fan. Ti ghten the
bol ts to 23 Nm (17 ft. l bs.) torque.
(14) Posi ti on the fan shroud and i nstal l the bol ts.
Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
(15) Fi l l cool i ng system (refer to Group 7, Cool i ng
System for the proper procedure).
(16) Connect the negati ve cabl e to the battery.
TIMING CHAIN
REMOVAL
(1) Remove Ti mi ng Chai n Cover Refer to proce-
dure i n thi s secti on.
(2) Remove camshaft sprocket attachi ng bol t and
remove ti mi ng chai n wi th crankshaft and camshaft
sprockets.
INSTALLATION
(1) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on exact
i magi nary center l i ne through both camshaft and
crankshaft bores.
(2) Pl ace ti mi ng chai n around both sprockets.
(3) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(4) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed).
(5) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 26).
(6) I nstal l the camshaft bol t. Ti ghten the bol t to 68
Nm (50 ft. l bs.) torque.
(7) Check camshaft end pl ay. The end pl ay shoul d
be 0.051-0.152 mm (0.002-0.006 i nch) wi th a new
thrust pl ate and up to 0.254 mm (0.010 i nch) wi th a
used thrust pl ate. I f not wi thi n these l i mi ts i nstal l a
new thrust pl ate.
CAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 27).
REMOVAL
(1) Remove i ntake mani fol d.
(2) Remove cyl i nder head covers.
(3) Remove ti mi ng case cover and ti mi ng chai n.
(4) Remove rocker arms.
(5) Remove push rods and tappets. I denti fy each
part so i t can be i nstal l ed i n i ts ori gi nal l ocati on.
(6) Remove di stri butor and l i ft out the oi l pump
and di stri butor dri ve shaft.
(7) Remove camshaft thrust pl ate, note l ocati on of
oi l tab (Fi g. 28).
(8) I nstal l a l ong bol t i nto front of camshaft to
faci l i tate removal of the camshaft. Remove camshaft,
Fig. 25 Installing Oil Seal
SPECIAL TOOL 6635
TIMING
CHAIN
COVER
Fig. 26 Alignment of Timing Marks
TIMING MARKS
Fig. 27 Camshaft and Sprocket Assembly
THRUST PLATE OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL WITH CAMSHAFT CAMSHAFTSPROCKET
9 - 102 5. 9L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
bei ng careful not to damage cam beari ngs wi th the
cam l obes.
INSTALLATION
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft to wi thi n 51 mm (2
i nches) of i ts fi nal posi ti on i n cyl i nder bl ock.
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
Mopar Crankcase Conditioner, or equivalent. The oil
mixture should be left in engine for a minimum of
805 km (500 miles). Drain at the next normal oil
change.
(2) I nstal l Camshaft Gear I nstal l er Tool C-3509
wi th tongue back of di stri butor dri ve gear (Fi g. 29).
(3) Hol d tool i n posi ti on wi th a di stri butor l ock-
pl ate bol t. Thi s tool wi l l restri ct camshaft from bei ng
pushed i n too far and prevent knocki ng out the wel ch
pl ug i n rear of cyl i nder bl ock. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) I nstal l camshaft thrust pl ate and chai n oi l tab.
Make sure tang enters lower right hole in
thrust plate. Ti ghten bol ts to 24 Nm (210 i n. l bs.)
torque. Top edge of tab shoul d be fl at agai nst thrust
pl ate i n order to catch oi l for chai n l ubri cati on.
(5) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on exact
i magi nary center l i ne through both camshaft and
crankshaft bores.
(6) Pl ace ti mi ng chai n around both sprockets.
(7) Turn crankshaft and camshaft to l i ne up wi th
keyway l ocati on i n crankshaft sprocket and i n cam-
shaft sprocket.
(8) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as descri bed).
(9) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and use a strai ghtedge to check al i gnment
of ti mi ng marks (Fi g. 30).
(10) I nstal l the camshaft bol t/cup washer. Ti ghten
bol t to 68 Nm (50 ft. l bs.) torque.
(11) Measure camshaft end pl ay. Refer to Speci fi ca-
ti ons for proper cl earance. I f not wi thi n l i mi ts i nstal l
a new thrust pl ate.
(12) Each tappet reused must be i nstal l ed i n the
same posi ti on from whi ch i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) Wi th engi ne compl etel y di sassembl ed, dri ve out
rear cam beari ng core hol e pl ug.
(2) I nstal l proper si ze adapters and horseshoe
washers (part of Camshaft Beari ng Remover/I nstal l er
Fig. 28 Timing Chain Oil Tab Installation
THRUST PLATE FRONT SIDE CHAIN OIL TAB THRUST PLATE REAR SIDE
Fig. 29 Camshaft Holding Tool C-3509
(InstalledPosition)
SPECIAL TOOL C-3509 DRIVE GEAR
DISTRIBUTOR LOCK BOLT
Fig. 30 Alignment of Timing Marks
TIMING MARKS
ZG 5. 9L ENGINE 9 - 103
REMOVAL AND INSTALLATION (Continued)
Tool C-3132-A) at back of each beari ng shel l . Dri ve
out beari ng shel l s (Fi g. 31).
INSTALLATION
(1) I nstal l new camshaft beari ngs wi th Camshaft
Beari ng Remover/I nstal l er Tool C-3132-A by sl i di ng
the new camshaft beari ng shel l over proper adapter.
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and i nstal l them
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) I denti fy beari ng caps before removal . Remove
beari ng caps one at a ti me.
(4) Remove upper hal f of beari ng by i nserti ng
Crankshaft Mai n Beari ng Remover/I nstal l er Tool
C-3059 i nto the oi l hol e of crankshaft (Fi g. 32).
(5) Sl owl y rotate crankshaft cl ockwi se, forci ng out
upper hal f of beari ng shel l .
INSTALLATION
Onl y one mai n beari ng shoul d be sel ecti vel y fi tted
whi l e al l other mai n beari ng caps are properl y ti ght-
ened. Al l beari ng capbol ts removed duri ng servi ce
procedures are to be cl eaned and oi l ed before i nstal -
l ati on.
When i nstal l i ng a new upper beari ng shel l , sl i ghtl y
chamfer the sharp edges from the pl ai n si de.
(1) Start beari ng i n pl ace, and i nsert Crankshaft
Mai n Beari ng Remover/I nstal l er Tool C-3059 i nto oi l
hol e of crankshaft (Fi g. 32).
(2) Sl owl y rotate crankshaft countercl ockwi se sl i d-
i ng the beari ng i nto posi ti on. Remove Tool C-3059.
(3) I nstal l the beari ng caps. Cl ean and oi l the
bol ts. Ti ghten the capbol ts to 115 Nm (85 ft. l bs.)
torque.
(4) I nstal l the oi l pump.
(5) I nstal l the oi l pan.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove di stri butor, refer to Group 8D, I gni ti on
Systems for the proper procedure.
(2) Remove the i ntake mani fol d (refer to Group 11,
Exhaust System and I ntake Mani fol d).
(3) I nsert Di stri butor Dri ve Shaft Bushi ng Pul l er
Tool C-3052 i nto ol d bushi ng and thread down unti l a
ti ght fi t i s obtai ned (Fi g. 33).
(4) Hol d pul l er screw and ti ghten pul l er nut unti l
bushi ng i s removed.
INSTALLATION
(1) Sl i de new bushi ng over burni shi ng end of Di s-
tri butor Dri ve Shaft Bushi ng Dri ver/Burni sher Tool
C-3053. I nsert the tool and bushi ng i nto the bore.
Fig. 31 Camshaft Bearings Removal/Installationwith
Tool C-3132-A
SPECIAL TOOL C-3132A MAIN BEARING OIL HOLE
Fig. 32 Upper Main Bearing Removal and
Installationwith Tool C-3059
SPECIAL TOOL C-3059 BEARING SPECIAL TOOL C-3059 BEARING INSTALLING REMOVING
Fig. 33 Distributor Driveshaft Bushing Removal
SPECIAL TOOL C-3052 BUSHING
9 - 104 5. 9L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(2) Dri ve bushi ng and tool i nto posi ti on, usi ng a
hammer (Fi g. 34).
(3) As the burni sher i s pul l ed through the bushi ng,
the bushi ng i s expanded ti ght i n the bl ock and bur-
ni shed to correct si ze (Fi g. 35). DO NOT ream this
bushing.
CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) I nstal l the i ntake mani fol d (refer to Group 11,
Exhaust System and I ntake Mani fol d).
DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil
pump drive shaft must be aligned to number one
cylinder.
(1) Rotate crankshaft unti l No.1 cyl i nder i s at top
dead center on the fi ri ng stroke.
(2) When i n thi s posi ti on, the ti mi ng mark of
vi brati on damper shoul d be under 0 on the ti mi ng
i ndi cator.
(3) I nstal l the shaft so that after the gear spi ral s
i nto pl ace, i t wi l l i ndex wi th the oi l pump shaft. The
sl ot on top of oi l pump shaft shoul d be al i gned
towards the l eft front i ntake mani fol d attachi ng bol t
hol e (Fi g. 36).
(4) I nstal l di stri butor, refer to Group 8D, I gni ti on
Systems for the proper procedure.
After the di stri butor has been i nstal l ed, i ts rota-
ti onal posi ti on must be set usi ng the SET SYNC
mode of the DRB scan tool . Refer to Checki ng Di s-
tri butor Posi ti on fol l owi ng the Di stri butor I nstal l a-
ti on secti on i n Group 8D, I gni ti on system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
effect fuel synchronization only.
OIL PAN
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Rai se the vehi cl e.
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Remove the oi l fi l ter.
(5) Remove the starter (refer to Group 8B, Battery/
Starter/Generator Servi ce).
(6) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(7) Posi ti on the cool er l i nes out of the way.
(8) Di sconnect the oxygen sensor.
(9) Remove exhaust pi pe.
(10) Remove the oi l pan bol ts. Careful l y sl i de the
oi l pan and gasket to the rear. I f equi pped wi th an oi l
l evel sensor, take care not to damage the sensor.
INSTALLATION
(1) Fabri cate 4 al i gnment dowel s from 5/16 x 1 1/2
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 37).
(2) I nstal l the dowel s i n the cyl i nder bl ock (Fi g.
38).
(3) Appl y smal l amount of Mopar Si l i cone Rubber
Adhesi ve Seal ant, or equi val ent i n the corner of the
cap and the cyl i nder bl ock.
(4) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock.
Fig. 34 Distributor Driveshaft Bushing Installation
SPECIAL TOOL C-3053 BUSHING
Fig. 35 Burnishing Distributor DriveshaftBushing
SPECIAL TOOLC-3053 BUSHING
Fig. 36 Position of Oil Pump Shaft Slot
DISTRIBUTORDRIVE
ZG 5. 9L ENGINE 9 - 105
REMOVAL AND INSTALLATION (Continued)
(5) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(6) I nstal l the oi l pan bol ts. Ti ghten the bol ts to 24
Nm (215 i n. l bs.) torque.
(7) Remove the dowel s. I nstal l the remai ni ng oi l
pan bol ts. Ti ghten these bol ts to 24 Nm (215 i n. l bs.)
torque.
(8) I nstal l the drai n pl ug. Ti ghten drai n pl ug to 34
Nm (25 ft. l bs.) torque.
(9) I nstal l exhaust pi pe.
(10) Connect the oxygen sensor.
(11) I nstal l the oi l fi l ter.
(12) I f equi pped wi th an oi l l evel sensor, connect
the sensor.
(13) I nstal l the starter (refer to Group 8B, Battery/
Starter/Generator Servi ce).
(14) Move the cool er l i nes back i nto posi ti on.
(15) Lower vehi cl e.
(16) Connect the negati ve cabl e to the battery.
(17) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(18) Start the engi ne and i nspect for l eaks.
PISTON AND CONNECTING ROD ASSEMBLY
REMOVAL
(1) Remove the engi ne from the vehi cl e.
(2) Remove the cyl i nder head.
(3) Remove the oi l pan.
(4) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pi stons covered
duri ng thi s operati on.
(5) Be sure the connecti ng rod and connecti ng rod
cap are i denti fi ed wi th the cyl i nder number. Remove
connecti ng rod cap. I nstal l connecti ng rod bol t gui de
set on connecti ng rod bol ts.
(6) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. When removi ng pi ston and
connecti ng rod assembl i es, rotate crankshaft to cen-
ter the connecti ng rod i n the cyl i nder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal , i nstal l beari ng cap on the mat-
i ng rod.
INSTALLATION
(1) Be sure that compressi on ri ng gaps are stag-
gered so that nei ther i s i n-l i ne wi th oi l ri ng rai l gap.
(2) Before i nstal l i ng the ri ng compressor, make
sure the oi l ri ng expander ends are butted and the
rai l gaps l ocated properl y (Fi g. 39).
Fig. 37 Fabrication of Alignment Dowels
5/16 X 1
1
2 BOLT DOWEL SLOT
Fig. 38 Position of Dowels in Cylinder Block
DOWEL DOWEL DOWEL DOWEL
Fig. 39 Proper Ring Installation
OIL RING SPACER GAP SECOND COM- PRESSION RING GAP OIL RING RAIL GAP (TOP) OIL RING RAIL GAP (BOTTOM) TOP COMPRES- SION RING GAP
9 - 106 5. 9L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l . Sl i de Pi ston Ri ng Compressor Tool C-385
over the pi ston and ti ghten wi th the speci al wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) I nstal l connecti ng rod bol t protectors on rod
bol ts, the l ong protector shoul d be i nstal l ed on the
numbered si de of the connecti ng rod.
(5) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. Be sure
connecti ng rod and cyl i nder bore number are the
same. I nsert rod and pi ston i nto cyl i nder bore and
gui de rod over the crankshaft journal .
(6) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on crankshaft journal .
(7) The notch or groove on top of pi ston must be
poi nti ng toward front of engi ne. The l arger chamfer
of the connecti ng rod bore must be i nstal l ed toward
crankshaft journal fi l l et.
(8) I nstal l rod caps. Be sure connecti ng rod, con-
necti ng rod cap and cyl i nder bore number are the
same. I nstal l nuts on cl eaned and oi l ed rod bol ts and
ti ghten nuts to 61 Nm (45 ft. l bs.) torque.
(9) I nstal l the oi l pan.
(10) I nstal l the cyl i nder head.
(11) I nstal l the engi ne i nto the vehi cl e.
CRANKSHAFT
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) Remove the vi brati on damper.
(4) Remove the ti mi ng chai n cover.
(5) I denti fy beari ng caps before removal . Remove
beari ng caps and beari ngs one at a ti me.
(6) Li ft the crankshaft out of the bl ock.
(7) Remove and di scard the crankshaft rear oi l
seal s.
(8) Remove and di scard the front crankshaft oi l
seal .
INSTALLATION
(1) Cl ean Locti te 518 resi due and seal ant from the
cyl i nder bl ock and rear cap mati ng surface. Do thi s
before appl yi ng the Locti te drop and the i nstal l ati on
of rear cap.
(2) Li ghtl y oi l the new upper seal l i ps wi th engi ne
oi l .
(3) I nstal l the new upper rear beari ng oi l seal wi th
the whi te pai nt faci ng towards the rear of the engi ne.
(4) Posi ti on the crankshaft i nto the cyl i nder bl ock.
(5) Li ghtl y oi l the new l ower seal l i ps wi th engi ne
oi l .
(6) I nstal l the new l ower rear beari ng oi l seal i nto
the beari ng cap wi th the whi te pai nt faci ng towards
the rear of the engi ne.
(7) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 40). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on.
(8) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(9) Cl ean and oi l al l cap bol ts. I nstal l al l mai n
beari ng caps. I nstal l al l cap bol ts and al ternatel y
ti ghten to 115 Nm (85 ft. l bs.) torque.
(10) I nstal l oi l pump.
(11) I nstal l the ti mi ng chai n cover.
(12) I nstal l the vi brati on damper.
(13) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent, at beari ng cap to bl ock joi nt to
provi de cap to bl ock and oi l pan seal i ng (Fi g. 41).
Appl y enough seal ant unti l a smal l amount i s
squeezed out. Wi thdraw nozzl e and wi pe excess seal -
ant off the oi l pan seal groove.
(14) I nstal l new front crankshaft oi l seal .
(15) I mmedi atel y i nstal l the oi l pan.
OIL PUMP
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from rear mai n beari ng
cap.
INSTALLATION
(1) I nstal l oi l pump. Duri ng i nstal l ati on sl owl y
rotate pump body to ensure dri veshaft-to-pump rotor
shaft engagement.
Fig. 40 Sealant Applicationto Bearing Cap
.25 DROP OF LOCTITE 515 ON BOTH SIDES OF REAR MAIN CAP
ZG 5. 9L ENGINE 9 - 107
REMOVAL AND INSTALLATION (Continued)
(2) Hol d the oi l pump base fl ush agai nst mati ng
surface on No.5 mai n beari ng cap. Fi nger ti ghten
pump attachi ng bol ts. Ti ghten attachi ng bol ts to 41
Nm (30 ft. l bs.) torque.
(3) I nstal l the oi l pan.
FRONT CRANKSHAFT OIL SEAL
The oi l seal can be repl aced wi thout removi ng the
ti mi ng chai n cover provi ded the cover i s not mi s-
al i gned.
(1) Di sconnect the negati ve cabl e from the battery.
(2) Remove vi brati on damper.
(3) I f front seal i s suspected of l eaki ng, check front
oi l seal al i gnment to crankshaft. The seal i nstal l a-
ti on/al i gnment tool 6635, shoul d fi t wi th mi ni mum
i nterference. I f tool does not fi t, the cover must be
removed and i nstal l ed properl y.
(4) Pl ace a sui tabl e tool behi nd the l i ps of the oi l
seal to pry the oi l seal outward. Be careful not to
damage the crankshaft seal bore of cover.
(5) Pl ace the smal l er di ameter of the oi l seal over
Front Oi l Seal I nstal l ati on Tool 6635 (Fi g. 42). Seat
the oi l seal i n the groove of the tool .
(6) Posi ti on the seal and tool onto the crankshaft
(Fi g. 43).
(7) Usi ng the vi brati on damper bol t, ti ghten the
bol t to draw the seal i nto posi ti on on the crankshaft
(Fi g. 44).
(8) Remove the vi brati on damper bol t and seal
i nstal l ati on tool .
(9) I nspect the seal fl ange on the vi brati on
damper.
Fig. 41 Apply Sealant to Bearing Cap to BlockJoint
MOPAR SILICONE RUB- BER ADHESIVE SEALANT NOZZLE TIP SEALANT APPLIED CYLINDER BLOCK REAR MAIN BEAR- ING CAP
Fig. 42 Placing Oil Seal on InstallationTool 6635
CRANKSHAFT FRONT OIL SEAL INSTALL THIS END INTO SPECIAL TOOL 6635
Fig. 43 Position Tool and Sealonto Crankshaft
SPECIAL TOOL 6635 OIL SEAL TIMING CHAIN COVER
Fig. 44 Installing Oil Seal
SPECIAL TOOL 6635
TIMING
CHAIN
COVER
9 - 108 5. 9L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(10) I nstal l the vi brati on damper.
(11) Connect the negati ve cabl e to the battery.
CRANKSHAFT REAR OIL SEALS
The servi ce seal i s a 2 pi ece, vi ton seal . The upper
seal hal f can be i nstal l ed wi th crankshaft removed
from engi ne or wi th crankshaft i nstal l ed. When a
new upper seal i s i nstal l ed, i nstal l a new l ower seal .
The l ower seal hal f can onl y be i nstal l ed wi th the
rear mai n beari ng cap removed.
UPPER SEAL CRANKSHAFT REMOVED
REMOVAL
(1) Remove the crankshaft. Di scard the ol d upper
seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock rear cap mati ng sur-
face. Make sure the seal groove i s free of debri s.
(2) Li ghtl y oi l the new upper seal l i ps wi th engi ne
oi l .
(3) I nstal l the new upper rear beari ng oi l seal wi th
the whi te pai nt faci ng towards the rear of the engi ne.
(4) Posi ti on the crankshaft i nto the cyl i nder bl ock.
(5) Li ghtl y oi l the new l ower seal l i ps wi th engi ne
oi l .
(6) I nstal l the new l ower rear beari ng oi l seal i nto
the beari ng cap wi th the whi te pai nt faci ng towards
the rear of the engi ne.
(7) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 45). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on.
(8) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(9) Cl ean and oi l al l cap bol ts. I nstal l al l mai n
beari ng caps. I nstal l al l cap bol ts and al ternatel y
ti ghten to 115 Nm (85 ft. l bs.) torque.
(10) I nstal l oi l pump.
(11) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent, at beari ng cap to bl ock joi nt to
provi de cap to bl ock and oi l pan seal i ng (Fi g. 46).
Appl y enough seal ant unti l a smal l amount i s
squeezed out. Wi thdraw nozzl e and wi pe excess seal -
ant off the oi l pan seal groove.
(12) I nstal l new front crankshaft oi l seal .
(13) I mmedi atel y i nstal l the oi l pan.
UPPER SEAL CRANKSHAFT INSTALLED
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) Remove the rear mai n beari ng cap. Remove
and di scard the ol d l ower oi l seal .
(4) Careful l y remove and di scard the ol d upper oi l
seal .
INSTALLATION
(1) Cl ean the cyl i nder bl ock mati ng surfaces before
oi l seal i nstal l ati on. Check for burr at the oi l hol e on
the cyl i nder bl ock mati ng surface to rear cap.
(2) Li ghtl y oi l the new upper seal l i ps wi th engi ne
oi l . To al l ow ease of i nstal l ati on of the seal , l oosen at
l east the 2 mai n beari ng caps forward of the rear
beari ng cap.
(3) Rotate the new upper seal i nto the cyl i nder
bl ock bei ng careful not to shave or cut the outer sur-
face of the seal . To assure proper i nstal l ati on, use the
i nstal l ati on tool provi ded wi th the ki t. I nstal l the
new seal wi th the whi te pai nt faci ng towards the
rear of the engi ne.
Fig. 45 Sealant Application to Bearing Cap
MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
LOCTITE 518 (OR EQUIVALENT) CAP ALIGNMENT SLOT REAR MAIN BEARING CAP
Fig. 46 Apply Sealant to Bearing Cap to BlockJoint
MOPAR SILICONE RUB- BER ADHESIVE SEALANT NOZZLE TIP SEALANT APPLIED CYLINDER BLOCK REAR MAIN BEAR- ING CAP
ZG 5. 9L ENGINE 9 - 109
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l the new l ower rear beari ng oi l seal i nto
the beari ng cap wi th the whi te pai nt faci ng towards
the rear of the engi ne.
(5) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 45). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on. Be sure the whi te pai nt faces toward the rear
of the engi ne.
(6) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(7) I nstal l the rear mai n beari ng cap wi th cl eaned
and oi l ed cap bol ts. Al ternatel y ti ghten ALL cap bol ts
to 115 Nm (85 ft. l bs.) torque.
(8) I nstal l oi l pump.
(9) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant,
or equi val ent, at beari ng cap to bl ock joi nt to provi de
cap to bl ock and oi l pan seal i ng (Fi g. 46). Appl y
enough seal ant unti l a smal l amount i s squeezed out.
Wi thdraw nozzl e and wi pe excess seal ant off the oi l
pan seal groove.
(10) I mmedi atel y i nstal l the oi l pan.
LOWER SEAL
REMOVAL
(1) Remove the oi l pan.
(2) Remove the oi l pump from the rear mai n bear-
i ng cap.
(3) Remove the rear mai n beari ng cap and di scard
the ol d l ower seal .
INSTALLATION
(1) Cl ean the rear mai n cap mati ng surfaces
i ncl udi ng the oi l pan gasket groove.
(2) Careful l y i nstal l a new upper seal (refer to
Upper Seal Repl acement - Crankshaft I nstal l ed pro-
cedure above).
(3) Li ghtl y oi l the new l ower seal l i ps wi th engi ne
oi l .
(4) I nstal l a new l ower seal i n beari ng cap wi th
the whi te pai nt faci ng the rear of engi ne.
(5) Appl y 5 mm (0.20 i n) drop of Locti te 518, or
equi val ent, on each si de of the rear mai n beari ng cap
(Fi g. 45). DO NOT over appl y seal ant or al l ow the
seal ant to contact the rubber seal . Assembl e beari ng
cap to cyl i nder bl ock i mmedi atel y after seal ant appl i -
cati on.
(6) To al i gn the beari ng cap, use cap sl ot, al i gn-
ment dowel and cap bol ts. DO NOT remove excess
materi al after assembl y. DO NOT stri ke rear cap
more than 2 ti mes for proper engagement.
(7) I nstal l the rear mai n beari ng cap wi th cl eaned
and oi l ed cap bol ts. Al ternatel y ti ghten the cap bol ts
to 115 Nm (85 ft. l bs.) torque.
(8) I nstal l oi l pump.
(9) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant,
or equi val ent, at beari ng cap to bl ock joi nt to provi de
cap to bl ock and oi l pan seal i ng (Fi g. 46). Appl y
enough seal ant unti l a smal l amount i s squeezed out.
Wi thdraw nozzl e and wi pe excess seal ant off the oi l
pan seal groove.
(10) I mmedi atel y i nstal l the oi l pan.
ENGINE CORE OIL AND CAMSHAFT PLUGS
Engi ne core pl ugs have been pressed i nto the oi l
gal l eri es behi nd the camshaft thrust pl ate (Fi g. 47).
Thi s wi l l reduce i nternal l eakage and hel p mai ntai n
hi gher oi l pressure at i dl e.
REMOVAL
(1) Usi ng a bl unt tool such as a dri ft or a screw-
dri ver and a hammer, stri ke the bottom edge of the
cup pl ug (Fi g. 48).
(2) Wi th the cup pl ug rotated, grasp fi rml y wi th
pl i ers or other sui tabl e tool and remove pl ug (Fi g.
48).
INSTALLATION
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Be certai n the new pl ug i s cl eaned of al l oi l or
grease.
(1) Coat edges of pl ug and core hol e wi th Mopar
Gasket Maker, or equi val ent.
CAUTION: DO NOT drive cup plug into the casting,
as restricted coolant flow can result and cause seri-
ous engine problems.
Fig. 47 Location of Cup Plugs in Oil Galleries
CUP PLUGS
9 - 110 5. 9L ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(2) Usi ng proper pl ug dri ve, dri ve cup pl ug i nto
hol e. The sharp edge of the pl ug shoul d be at l east
0.50 mm (0.020 i n.) i nsi de the l ead-i n chamfer.
(3) I t i s not necessary to wai t for curi ng of the
seal ant. The cool i ng system can be fi l l ed and the
vehi cl e pl aced i n servi ce i mmedi atel y.
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis-
assemble a tappet on a dirty work bench.
DISASSEMBLE
(1) Pry out pl unger retai ner spri ng cl i p (Fi g. 49).
(2) Cl ean varni sh deposi ts from i nsi de of tappet
body above pl unger cap.
(3) I nvert tappet body and remove pl unger cap,
pl unger, check val ve, check val ve spri ng, check val ve
retai ner and pl unger spri ng (Fi g. 49). Check val ve
coul d be fl at or bal l .
ASSEMBLE
(1) Cl ean al l tappet parts i n a sol vent that wi l l
remove al l varni sh and carbon.
(2) Repl ace tappets that are unfi t for further ser-
vi ce wi th new assembl i es.
(3) I f pl unger shows si gns of scori ng or wear,
i nstal l a new tappet assembl y. I f val ve i s pi tted, or
val ve seat on end of pl unger i s prevented from seat-
i ng, i nstal l a new tappet assembl y.
(4) Assembl e tappets (Fi g. 49).
VALVE SERVICE
VALVE GUIDES
Measure val ve stem gui de cl earance as fol l ows:
(1) I nstal l Val ve Gui de Sl eeve Tool C-3973 over
val ve stem and i nstal l val ve (Fi g. 50). The speci al
sl eeve pl aces the val ve at the correct hei ght for
checki ng wi th a di al i ndi cator.
(2) Attach Di al I ndi cator Tool C-3339 to cyl i nder
head and set i t at ri ght angl e of val ve stem bei ng
measured (Fi g. 51).
(3) Move val ve to and from the i ndi cator. The total
di al i ndi cator readi ng shoul d not exceed 0.432 mm
(0.017 i nch). Ream the gui des for val ves wi th over-
Fig. 48 Core Hole Plug Removal
CYLINDER BLOCK SECOND REMOVE PLUG WITH PLI- ERS FIRST STRIKE HERE WITH HAMMER DRIFT CUP PLUG
Fig. 49 Hydraulic Tappet Assembly
PLUNGERSPRING CHECK BALLPLUNGER PLUNGER RETAINER SPRING CLIP PLUNGER CAP CHECK VALVE SPRING RETAINER ROLLER TAP- PET BODY
Fig. 50 Positioning Valve with Tool C-3973
VALVE SPACER TOOL
Fig. 51 Measuring Valve Guide Wear
VALVE SPECIAL TOOL C-3339
ZG 5. 9L ENGINE 9 - 111
REMOVAL AND INSTALLATION (Continued)
si ze stems i f di al i ndi cator readi ng i s excessi ve or i f
the stems are scuffed or scored.
(4) Servi ce val ves wi th oversi ze stems are avai l -
abl e (Fi g. 52).
(5) Sl owl y turn reamer by hand and cl ean gui de
thoroughl y before i nstal l i ng new val ve. Ream the
valve guides from standard to 0.381 mm (0.015
inch). Use a 2 step procedure so the valve
guides are reamed true in relation to the valve
seat:
Step 1Ream to 0.0763 mm (0.003 i nch).
Step 2Ream to 0.381 mm (0.015 i nch).
REFACING VALVES AND VALVE SEATS
The i ntake and exhaust val ves have a 43-1/4 to
43-3/4 face angl e and a 44-1/4 to 44-3/4 seat angl e
(Fi g. 53).
VALVES
I nspect the remai ni ng margi n after the val ves are
refaced (Fi g. 54). Val ves wi th l ess than 1.190 mm
(0.047 i nch) margi n shoul d be di scarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 55).
(1) When refaci ng val ve seats, i t i s i mportant that
the correct si ze val ve gui de pi l ot be used for reseat-
i ng stones. A true and compl ete surface must be
obtai ned.
(2) Measure the concentri ci ty of val ve seat usi ng a
di al i ndi cator. Total runout shoul d not exceed 0.051
mm (0.002 i nch) total i ndi cator readi ng.
(3) I nspect the val ve seat wi th Prussi an bl ue to
determi ne where the val ve contacts the seat. To do
thi s, coat val ve seat LI GHTLY wi th Prussi an bl ue
then set val ve i n pl ace. Rotate the val ve wi th l i ght
Fig. 52 Reamer Sizes
Fig. 53 Valve Face and Seat Angles
CONTACT POINT A SEAT WIDTH INTAKE 1.016 1.524 mm (0.040 0.060 in.) EXHAUST 1.524 2.032 mm (0.060 0.080 in.) B FACE ANGLE (INTAKE & EXHAUST) 43
1
4 43
3
4 C SEAT ANGLE (INTAKE & EXHAUST) 44
1
4 44
3
4 D CONTACT SURFACE
Fig. 54 Intake and Exhaust Valves
INTAKE VALVE MARGIN EXHAUST VALVE VALVE SPRING RETAINER LOCKGROOVE STEM
FACE
Fig. 55 Refacing Valve Seats
REFACING STONE
MUST NOT CUT VALVE
SHROUD
STONE
PILOT VALVE SEAT SHROUD
9 - 112 5. 9L ENGINE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
pressure. I f the bl ue i s transferred to the center of
val ve face, contact i s sati sfactory. I f the bl ue i s trans-
ferred to the top edge of val ve face, l ower val ve seat
wi th a 15 stone. I f the bl ue i s transferred to bottom
edge of val ve face rai se val ve seat wi th a 60 stone.
(4) When seat i s properl y posi ti oned the wi dth of
i ntake seats shoul d be 1.016-1.524 mm (0.040-0.060
i nch). The wi dth of the exhaust seats shoul d be
1.524-2.032 mm (0.060-0.080 i nch).
VALVE SPRING INSPECTION
Whenever val ves have been removed for i nspecti on,
recondi ti oni ng or repl acement, val ve spri ngs shoul d
be tested. As an exampl e the compressi on l ength of
the spri ng to be tested i s 1-5/16 i nch. Turn tabl e of
Uni versal s Val ve Spri ng Tester Tool unti l surface i s
i n l i ne wi th the 1-5/16 i nch mark on the threaded
stud. Be sure the zero mark i s to the front (Fi g. 56).
Pl ace spri ng over stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l pi ng i s heard. Take readi ng on torque wrench
at thi s i nstant. Mul ti pl y thi s readi ng by 2. Thi s wi l l
gi ve the spri ng l oad at test l ength. Fracti onal mea-
surements are i ndi cated on the tabl e for fi ner adjust-
ments. Refer to speci fi cati ons to obtai n speci fi ed
hei ght and al l owabl e tensi ons. Di scard the spri ngs
that do not meet speci fi cati ons.
OIL PUMP
DISASSEMBLE
(1) Remove the rel i ef val ve as fol l ows:
(a) Remove cotter pi n. Dri l l a 3.175 mm (1/8
i nch) hol e i nto the rel i ef val ve retai ner cap and
i nsert a sel f-threadi ng sheet metal screw.
(b) Cl amp screw i nto a vi se and whi l e support-
i ng oi l pump, remove cap by tappi ng pump body
usi ng a soft hammer. Di scard retai ner cap and
remove spri ng and rel i ef val ve (Fi g. 57).
(2) Remove oi l pump cover (Fi g. 58).
(3) Remove pump outer rotor and i nner rotor wi th
shaft (Fi g. 58).
(4) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
ASSEMBLE
(1) I nstal l pump rotors and shaft, usi ng new parts
as requi red.
(2) Posi ti on the oi l pump cover onto the pump
body. Ti ghten cover bol ts to 11 Nm (95 i n. l bs.)
torque.
(3) I nstal l the rel i ef val ve and spri ng. I nsert the
cotter pi n.
(4) Tap on a new retai ner cap.
(5) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
CYLINDER BLOCK
DISASSEMBLE
Engi ne assembl y removed from vehi cl e:
(1) Remove the cyl i nder head.
(2) Remove the oi l pan.
(3) Remove the pi ston and connecti ng rod assem-
bl i es.
Fig. 56 Testing Valve Spring for CompressedLength
TORQUE WRENCH VALVE SPRING TESTER
Fig. 57 Oil Pressure Relief Valve
OIL PUMP ASSEMBLY COTTER PIN RELIEF VALVE RETAINERCAP SPRING
Fig. 58 Oil Pump
INNER ROTOR AND SHAFT BODY DISTRIBUTOR DRIVESHAFT (REFERENCE) COTTER PIN RETAINERCAP SPRING RELIEF VALVE LARGE CHAMFERED EDGE BOLT COVER OUTERROTOR
ZG 5. 9L ENGINE 9 - 113
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLE
(1) I nstal l the pi ston and connecti ng rod assembl y.
(2) I nstal l the oi l pan.
(3) I nstal l the cyl i nder head.
(4) I nstal l the engi ne i nto the vehi cl e.
CLEANING AND INSPECTION
CYLINDER HEADS
CLEANING
Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
Cl ean cyl i nder bl ock front and rear gasket surfaces
usi ng a sui tabl e sol vent.
INSPECTION
I nspect al l surfaces wi th a strai ghtedge i f there i s
any reason to suspect l eakage. I f out-of-fl atness
exceeds 0.00075 mm/mm (0.00075 i nch/i nch) ti mes
the span l ength i n i nches i n any di recti on, ei ther
repl ace head or l i ghtl y machi ne the head surface.
FOR EXAMPLE: A 305 mm (12 i nch) span i s
0.102 mm (0.004 i nch) out-of-fl at. The al l owabl e out-
of-fl at i s 305 x 0.00075 (12 x 0.00075) equal s 0.23
mm (0.009 i nch). Thi s amount of out-of-fl at i s accept-
abl e.
The cyl i nder head surface fi ni sh shoul d be
1.78-3.00 mi crons (70-125 mi cro i nches).
I nspect push rods. Repl ace worn or bent rods.
PISTON AND CONNECTING ROD ASSEMBLY
INSPECTION
Check the crankshaft connecti ng rod journal for
excessi ve wear, taper and scori ng.
Check the cyl i nder bl ock bore for out-of-round,
taper, scori ng and scuffi ng.
Check the pi stons for taper and el l i pti cal shape
before they are fi tted i nto the cyl i nder bore (Fi g. 59).
CRANKSHAFT JOURNALS
The crankshaft connecti ng rod and mai n journal s
shoul d be checked for excessi ve wear, taper and scor-
i ng. The maxi mum taper or out-of-round on any
crankshaft journal i s 0.025 mm (0.001 i nch).
Journal gri ndi ng shoul d not exceed 0.305 mm
(0.012 i nch) under the standard journal di ameter. DO
NOT gri nd thrust faces of No.3 mai n beari ng. DO
NOT ni ck crank pi n or beari ng fi l l ets. After gri ndi ng,
remove rough edges from crankshaft oi l hol es and
cl ean out al l oi l passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.
OIL PAN
CLEANING
Cl ean the bl ock and pan gasket surfaces.
Tri m or remove excess seal ant fi l m i n the rear
mai n cap oi l pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
I f present, tri m excess seal ant from i nsi de the
engi ne.
Cl ean oi l pan i n sol vent and wi pe dry wi th a cl ean
cl oth.
Cl ean oi l screen and pi pe thoroughl y i n cl ean sol -
vent. I nspect condi ti on of screen.
INSPECTION
I nspect oi l drai n pl ug and pl ug hol e for stri pped or
damaged threads. Repai r as necessary.
I nspect oi l pan mounti ng fl ange for bends or di stor-
ti on. Strai ghten fl ange, i f necessary.
OIL PUMP
INSPECTION
Mati ng surface of the oi l pump cover shoul d be
smooth. Repl ace pump assembl y i f cover i s scratched
or grooved.
Lay a strai ghtedge across the pump cover surface
(Fi g. 60). I f a 0.038 mm (0.0015 i nch) feel er gauge
Fig. 59 Piston Measurements5.9L
PISTON PIN BORE DIAME- TER 25.007 25.015 mm (.9845 .9848 IN.)
9 - 114 5. 9L ENGINE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
can be i nserted between cover and strai ghtedge,
pump assembl y shoul d be repl aced.
Measure thi ckness and di ameter of OUTER rotor.
I f outer rotor thi ckness measures 20.9 mm (0.825
i nch) or l ess or i f the di ameter i s 62.7 mm (2.469
i nches) or l ess, repl ace outer rotor (Fi g. 61).
I f i nner rotor measures 20.9 mm (0.825 i nch) or
l ess, repl ace i nner rotor and shaft assembl y (Fi g. 62).
Sl i de outer rotor i nto pump body. Press rotor to the
si de wi th your fi ngers and measure cl earance
between rotor and pump body (Fi g. 63). I f cl earance
i s 0.356 mm (0.014 i nch) or more, repl ace oi l pump
assembl y.
I nstal l i nner rotor and shaft i nto pump body. I f
cl earance between i nner and outer rotors i s 0.203
mm (0.008 i nch) or more, repl ace shaft and both
rotors (Fi g. 64).
Pl ace a strai ghtedge across the face of the pump,
between bol t hol es. I f a feel er gauge of 0.102 mm
(0.004 i nch) or more can be i nserted between rotors
and the strai ghtedge, repl ace pump assembl y (Fi g.
65).
I nspect oi l pressure rel i ef val ve pl unger for scori ng
and free operati on i n i ts bore. Smal l marks may be
removed wi th 400-gri t wet or dry sandpaper.
The rel i ef val ve spri ng has a free l ength of approx-
i matel y 49.5 mm (1.95 i nches). The spri ng shoul d
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 i nches). Repl ace spri ng that fai l s
to meet these speci fi cati ons (Fi g. 66).
Fig. 60 Checking Oil Pump Cover Flatness
COVER STRAIGHT EDGE FEELER GAUGE
Fig. 61 Measuring Outer Rotor Thickness
Fig. 62 Measuring Inner Rotor Thickness
Fig. 63 Measuring Outer Rotor Clearance inHousing
PUMP BODY OUTER ROTOR FEELER GAUGE
Fig. 64 Measuring Clearance Between Rotors
OUTER ROTOR FEELER GAUGE INNER ROTOR
ZG 5. 9L ENGINE 9 - 115
CLEANING AND INSPECTION (Continued)
I f oi l pressure was l ow and pump i s wi thi n speci fi -
cati ons, i nspect for worn engi ne beari ngs or other
reasons for oi l pressure l oss.
CYLINDER BLOCK
CLEANING
Cl ean cyl i nder bl ock thoroughl y and check al l core
hol e pl ugs for evi dence of l eaki ng.
INSPECTION
Exami ne bl ock for cracks or fractures.
The cyl i nder wal l s shoul d be checked for out-of-
round and taper wi th Cyl i nder Bore I ndi cator Tool
C-119. The cyl i nder bl ock shoul d be bored and honed
wi th new pi stons and ri ngs fi tted i f:
The cyl i nder bores show more than 0.127 mm
(0.005 i n.) out-of-round.
The cyl i nder bores show a taper of more than
0.254 mm (0.010 i n.).
The cyl i nder wal l s are badl y scuffed or scored.
Bori ng and honi ng operati on shoul d be cl osel y coor-
di nated wi th the fi tti ng of pi stons and ri ngs, so that
speci fi ed cl earances can be mai ntai ned.
OIL LINE PLUG
The oi l l i ne pl ug i s l ocated i n the verti cal passage
at the rear of the bl ock between the oi l -to-fi l ter and
oi l -from-fi l ter passages (Fi g. 67). I mproper i nstal l a-
ti on or pl ug mi ssi ng coul d cause errati c, l ow, or no oi l
pressure.
The oi l pl ug must come out the bottom. Use fl at
dowel , down the oi l pressure sendi ng uni t hol e from
the top, to remove oi l pl ug.
(1) Remove oi l pressure sendi ng uni t from back of
bl ock.
(2) I nsert a 3.175 mm (1/8 i n.) fi ni sh wi re, or
equi val ent, i nto passage.
(3) Pl ug shoul d be 190.0 to 195.2 mm (7-1/2 to
7-11/16 i n.) from machi ned surface of bl ock (Fi g. 67).
I f pl ug i s too hi gh, use a sui tabl e fl at dowel to posi -
ti on properl y.
(4) I f pl ug i s too l ow, remove oi l pan and No. 4
mai n beari ng cap. Use sui tabl e fl at dowel to posi ti on
properl y. Coat outsi de di ameter of pl ug wi th Mopar
Stud and Beari ng Mount Adhesi ve, or equi val ent.
Pl ug shoul d be 54.0 to 57.7 mm (2-1/8 to 2-5/16 i n.)
from bottom of the bl ock.
Fig. 65 Measuring Clearance Over Rotors
STRAIGHT EDGE FEELER GAUGE
Fig. 66 Proper Installation of Retainer Cap
RETAINER CAP CHAMFER COTTER KEY
Fig. 67 Oil Line Plug
RIGHT OIL GALLERY CYLINDER BLOCK OIL FROM FIL- TER TO SYS- TEM OIL TO FILTER FROM OIL PUMP CRANKSHAFT
PLUG
9 - 116 5. 9L ENGINE ZG
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
5. 9L ENGINE
Camshaft
Beari ng Di ameter
No. 1 . . . . . 50.800 50.825 mm (2.000 2.001 i n)
No. 2 . . . . . 50.394 50.419 mm (1.984 1.985 i n)
No. 3 . . . . . 50.013 50.038 mm (1.969 1.970 i n)
No. 4 . . . . . 49.606 49.632 mm (1.953 1.954 i n)
No. 5 . . . . . . . . . . . . . . . . . . . . 39.688 39.713 mm
(1.5625 1.5635 i n)
Di ametri cal Cl earance . . . . . . 0.0254 0.0762 mm
(0.001 0.003 i n)
Max. Al l owabl e . . . . . . . . . . . . . 0.127 mm (0.005 i n)
End Pl ay . . . . . . . . . . . . . . . . . . . 0.051 0.254 mm
(0.002 0.010 i n)
Beari ng Journal Di ameter . . . . . . . . . . . . . . . . . . . .
No. 1 . . . . . 50.749 50.775 mm (1.998 1.999 i n)
No. 2 . . . . . 50.343 50.368 mm (1.982 1.983 i n)
No. 3 . . . . . 49.962 49.987 mm (1.967 1.968 i n)
No. 4 . . . . . 49.555 49.581 mm (1.951 1.952 i n)
No. 5 . . . 39.637 39.662 mm (1.5605 1.5615 i n)
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . .
Beari ng Cl earance . . . . . . . . . . . 0.013 0.056 mm
(0.0005 0.0022 i n)
Max. Al l owabl e . . . . . . . . . . . . . . . 0.08 mm (.003 i n)
Pi ston Pi n Bore Di ameter . . . . 24.966 24.978 mm
(0.9829 0.9834 i n)
Si de Cl earance (Two Rods) . . . . . 0.152 0.356 mm
(0.006 0.014 i n)
Total Wei ght (Less Beari ng) . . . 758 grams (25.74 oz)
Crankshaft
Connecti ng Rod Journal Di ameter . 53.950 53.975
mm
(2.124 2.125 i n)
Out-of-Round (Max.) . . . . . . . . . . . . . . . . 0.0254 mm
(0.001 i n)
Taper (Max.) . . . . . . . . . . . . . . 0.0254 mm (0.001 i n)
Di ametri cal Cl earance . . . . . . . . . . . . . . . . . . . . . . . .
No. 1 . . . . . 0.013 0.038 mm (0.0005 0.0015 i n)
Max. Al l owabl e (No. 1) . . . . . 0.0381 mm (0.0015 i n)
Nos. 2, 3, 4 and 5 . . . . . . . . . . . . 0.013 0.051 mm
(0.005 0.0020 i n)
Max. Al l owabl e (Nos. 2, 3, 4 & 5) . . . . . . . 0.064 mm
(0.0025 i n)
End Pl ay . . . . . . . . . . . . . . . . . . . 0.051 0.178 mm
(0.002 0.007 i n)
Max. Al l owabl e . . . . . . . . . . . . . 0.254 mm (0.010 i n)
Mai n Beari ng Journal s
Di ameter . . . . . . . . . . . . . . . . . 71.361 71.387 mm
(2.8095 2.8105 i n)
Out-of-Round (Max.) . . . . . . . . . . . . . . . . 0.0254 mm
(0.001 i n)
Taper (Max.) . . . . . . . . . . . . . . 0.0254 mm (0.001 i n)
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cyl i nder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Di ameter . . 101.60 101.65 mm (4.000 4.002 i n)
Out-of-Round (Max.) . . . . . . . . . 0.127 mm (0.005 i n)
Taper (Max.) . . . . . . . . . . . . . . . 0.254 mm (0.010 i n)
Di stri butor Lower Dri ve Shaft Bushi ng
(Press Fi t i n Bl ock) . 0.0127 0.3556 mm (0.0005
0.0140 i n)
Shaft-to-Bushi ng Cl earance . . 0.0178 0.0686 mm
(0.0007 0.0027 i n)
Tappet Bore Di ameter . . . . . . . . 22.99 23.01 mm
(0.9051 0.9059 i n)
Cylinder Head
Compressi on Pressure . . . . . . . . . 689 kPa (100 psi )
Gasket Thi ckness (Compressed) . . . . . . . 1.2065 mm
(0.0475 i n)
Val ve Seat
Angl e . . . . . . . . . . . . . . . . . . . . . . . . 44.25 44.75
Runout (Max.) . . . . . . . . . . . . . 0.0762 mm (0.003 i n)
Wi dth (Fi ni sh) I ntake . . . . . . . 1.016 1.524 mm
(0.040 0.060 i n)
Wi dth (Fi ni sh) Exhaust . . . . . 1.524 2.032 mm
(0.060 0.080 i n)
Hydraulic Tappets
Body Di ameter . . . . . . . . . . . . 22.949 22.962 mm
(0.9035 0.9040 i n)
Cl earance i n Bl ock . . . . . . . . . 0.0279 0.0610 mm
(0.0011 0.0024 i n)
Dry Lash . . . . . . . . . . . . . . . . . . 1.524 5.334 mm
(0.060 0.210 i n)
Push Rod Length . . . . . . . . . . 175.64 176.15 mm
(6.915 6.935 i n)
ENGINE SPECIFICATIONS
ZG 5. 9L ENGINE 9 - 117
Oil Pump
Cl earance over Rotors (Max.) . 0.1016 mm (0.004 i n)
Cover Out-of-Fl at (Max.) . . . . 0.0381 mm (0.0015 i n)
I nner Rotor Thi ckness (Mi n.) . 20.955 mm (0.825 i n)
Outer Rotor
Cl earance (Max.) . . . . . . . . . . . 0.3556 mm (0.014 i n)
Di ameter (Mi n.) . . . . . . . . . . 62.7126 mm (2.469 i n)
Thi ckness (Mi n.) . . . . . . . . . . . 20.955 mm (0.825 i n)
Ti p Cl earance between Rotors (Max.) . . . 0.2032 mm
(0.008 i n)
Oil Pressure
At Curb I dl e Speed (Mi ni mum)* . . . 41.4 kPa (6 psi )
At 3000 rpm . . . . . . . . 207 552 kPa (30 80 psi )
Swi tch Actuati ng Pressure (Mi n.) . . 34.5 48.3 kPa
(57 psi )
*CAUTI ON: I f pressure i s ZERO at curb i dl e, DO NOT
run engi ne at 3,000 rpm.
Oil Filter
Bypass Val ve Setti ng . . . . . 62 103 kPa (915 psi )
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cl earance at Top of Ski rt . . . . . . 0.013 0.038 mm
(0.0005 0.0015 i n)
Land Cl earance (Di ametri cal ) . . . 0.508 0.660 mm
(0.020 0.026 i n)
Pi ston Length . . . . . . . . . . . . . . . 81.03 mm (3.19 i n)
Pi ston Ri ng Groove Depth
Nos. 1 and 2 . . . . . . . . . . . . . . . . 4.761 4.912 mm
(0.187 0.193 i n)
No. 3 . . . . . . . 3.996 4.177 mm (0.157 0.164 i n)
Wei ght . . . . . . 582 586 grams (20.53 20.67 oz)
Piston Pins
Cl earance I n Pi ston . . . . . . . . . . 0.006 0.019 mm
(0.00023 0.00074 i n)
Di ameter . . . . . . . . . . . . . . . . . 25.007 25.015 mm
(0.9845 0.9848 i n)
End Pl ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . NONE
Length . . . . . . . . . 67.8 68.3 mm (2.67 2.69 i n)
Piston Rings
Ri ng Gap
Compressi on Ri ng (Top) . . . . . . . . . 0.30 0.55 mm
(0.012 0.022 i n)
Compressi on Ri ngs (2nd) . . . . . . . . 0.55 0.80 mm
(0.022 0.031 i n)
Oi l Control (Steel Rai l s) . . . . . . . 0.381 1.397 mm
(0.015 0.055 i n)
Ri ng Si de Cl earance
Compressi on Ri ngs . . . . . . . . . . . 0.040 0.085 mm
(0.0016 0.0033 i n)
Oi l Ri ng (Steel Rai l s) . . . . . . . . . . . 0.05 0.21 mm
(0.002 0.008 i n)
Ri ng Wi dth
Compressi on Ri ngs . . . . . . . . . . . 1.530 1.555 mm
(0.060 0.061 i n)
Oi l Ri ng (Steel Rai l s) Max. . . . 0.447 0.473 mm
(0.018 0.019 i n)
Valves
Face Angl e . . . . . . . . . . . . . . . . . . . 43.25 43.75
Head Di ameter
I ntake . . . . . . . . . . . . . . . . . . . . 47.752 mm (1.88 i n)
Exhaust . . . . . . . . . . . . . . . . . 41.072 mm (1.617 i n)
Length (Overal l )
I ntake . . . . 126.21 126.85 mm (4.969 4.994 i n)
Exhaust . . . 126.44 127.30 mm (4.978 5.012 i n)
Li ft (Zero Lash) . . . . . . . . . . . . 10.414 mm (0.410 i n)
Stem Di ameter
I ntake . . . . . . 9.449 9.474 mm (0.372 0.373 i n)
Exhaust . . . . 9.423 9.449 mm (0.371 0.372 i n)
Stem-to-Gui de Cl earance . . . . . . . . . . . . . . . . . . . . .
I ntake . . . . 0.0254 0.0762 mm (0.001 0.003 i n)
Exhaust . . . 0.0508 0.1016 mm (0.002 0.004 i n)
Max. Al l owabl e (Rocki ng Method) . . . . . . 0.4318 mm
(0.017 i n)
Gui de Bore Di ameter (Std) . . . . . 9.500 9.525 mm
(0.374 0.375 i n)
Valve Springs
Free Length (Approx.) . . . . . . . 49.962 mm (1.967 i n)
Spri ng Tensi on (Val ve Cl osed) . @ 41.66 mm = 378 N
(@ 1.64 i n = 85 l bs)
Spri ng Tensi on (Val ve Open) . . @ 30.89 mm = 890 N
(@ 1.212 i n = 200 l bs)
Number of Coi l s . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
I nstal l ed Hei ght
(Spri ng Seat to Retai ner) . . . . 41.66 mm (1.64 i n)
Wi re Di ameter . . . . . . . . . . . . . . 4.50 mm (0.177 i n)
Valve Timing
Exhaust Val ve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cl oses (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Opens (BBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
I ntake Val ve
Cl oses (ABC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Opens (BTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Durati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . . . 36.5
ENGINE SPECIFICATIONSCONT.
9 - 118 5. 9L ENGINE ZG
SPECIFICATIONS (Continued)
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS
CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION
0.025 mm (0.001 inch) U/S
Crankshaft
R or M
M-2-3 etc (Indicating No. 2 & 3
main bearing journal)
and/or
R-1-4 etc. (Indicating No. 1 & 4
connecting rod journal)
Milled flat on number three
crankshaft counterweight
0.508 mm (0.020 inch) O/S Cylinder
Bores
A Following engine serial number.
0.203 mm (0.008 inch) O/S Tappets 3/8 diamond-shaped stamp Top pad
- Front of engine and flat ground on
outside surface of each O/S tappet
bore.
0.127 mm (0.005 inch) O/S Valve
Stems
X Milled pad adjacent to two 3/8
tapped holes on each end of cylinder
head.
TORQUE
5.9L ENGINE
DESCRIPTION TORQUE
Adjusting Strap
Bol t . . . . . . . . . . . . . . . . . . . . 23 Nm (200 i n. l bs.)
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . . 68 Nm (50 ft. l bs.)
Camshaft Thrust Plate
Bol ts . . . . . . . . . . . . . . . . . . . . 24 Nm (18 ft. l bs.)
Chain Case Cover
Bol ts . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Connecting Rod Cap
Bol ts . . . . . . . . . . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Crankshaft Main Bearing Cap
Bol ts . . . . . . . . . . . . . . . . . . . 115 Nm (85 ft. l bs.)
Crankshaft Pulley
Bol ts . . . . . . . . . . . . . . . . . . . 24 Nm (210 i n. l bs.)
Cylinder Head Bolts
Step 1 I ni ti al . . . . . . . . . . . . 68 Nm (50 ft. l bs.)
Step 2 Fi nal . . . . . . . . . . . 143 Nm (105 ft. l bs.)
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . . 11 Nm (95 i n. l bs.)
Exhaust Manifold to Cylinder Head
Bol ts/Nuts . . . . . . . . . . . . . . . . 34 Nm (25 ft. l bs.)
Flywheel
Bol ts . . . . . . . . . . . . . . . . . . . . 75 Nm (55 ft. l bs.)
Front Engine Mount Bracket to Block
Bol ts . . . . . . . . . . . . . . . . . . . . 81 Nm (60 ft. l bs.)
Front Engine Mount
Through Bol t/Nut . . . . . . . . . . 68 Nm (50 ft. l bs.)
Generator Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
DESCRIPTION TORQUE
Intake Manifold
Bol ts . . . . . . . . . Refer to procedure i n thi s secti on
Oil Pan
Bol ts . . . . . . . . . . . . . . . . . . . 24 Nm (215 i n. l bs.)
Oil Pan Drain Plug
Pl ug . . . . . . . . . . . . . . . . . . . . . 34 Nm (25 ft. l bs.)
Oil Pump
Bol ts . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Oil Pump Cover
Bol ts . . . . . . . . . . . . . . . . . . . . 11 Nm (95 i n. l bs.)
Rear Mount Insulator to Support Bracket
Nuts . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Rear Mount Insulator to Crossmember
Nut . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Rear Support Bracket to Transmission
Bol ts . . . . . . . . . . . . . . . . . . . 102 Nm (75 ft. l bs.)
Rocker Arm
Bol ts . . . . . . . . . . . . . . . . . . . . 28 Nm (21 ft. l bs.)
Spark Plugs
Pl ugs . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Starter Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . 68 Nm (50 ft. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . 25 Nm (225 i n. l bs.)
Throttle Body
Bol ts . . . . . . . . . . . . . . . . . . . 23 Nm (200 i n. l bs.)
Torque Converter Drive Plate
Bol ts . . . . . . . . . . . . . . . . . . . 31 Nm (270 i n. l bs.)
ZG 5. 9L ENGINE 9 - 119
SPECIFICATIONS (Continued)
DESCRIPTION TORQUE
Transmission Support Bracket
Bol ts . . . . . . . . . . . . . . . . . . . 102 Nm (75 ft. l bs.)
Transmission Support Spacer to Insulator
Mounting Plate (4wd)
Nuts . . . . . . . . . . . . . . . . . . 204 Nm (150 ft. l bs.)
Vibration Damper
Bol t . . . . . . . . . . . . . . . . . . . 183 Nm (135 ft. l bs.)
Water Pump to Chain Case Cover
Bol t . . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
SPECIAL TOOLS
5. 9L ENGINE
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487A
Valve Spring Compressor MD-998772A
Adaptor 6633
Adaptor 6716A
Valve Guide Sleeve C-3973
9 - 120 5. 9L ENGINE ZG
SPECIFICATIONS (Continued)
Dial Indicator C-3339
Puller C-3688
Front Oil Seal Installer 6635
Cam Bearing Remover/Installer C-3132A
Camshaft Holder C-3509
Distributor Bushing Puller C-3052
Distributor Bushing Driver/BurnisherC-3053
Piston Ring Compressor C-385
ZG 5. 9L ENGINE 9 - 121
SPECIAL TOOLS (Continued)
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
9 - 122 5. 9L ENGINE ZG
SPECIAL TOOLS (Continued)
ENGINE
CONTENTS
page page
GENERAL INFORMATION
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . 1
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
SERVICE DIAGNOSISDIESEL
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE DIAGNOSISDIESEL
MECHANICAL. . . . . . . . . . . . . . . . . . . . . . . . . 9
TAPPET NOISE . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE PROCEDURES
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL AND INSTALLATION
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 15
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . 17
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 18
ROCKER ARMS AND PUSH RODS . . . . . . . . . 19
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . . 20
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . 24
TIMING CASE COVER OIL SEAL . . . . . . . . . . . 25
TIMING CASE COVER . . . . . . . . . . . . . . . . . . . 25
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . 27
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INTERNAL VACUUM PUMP . . . . . . . . . . . . . . . 28
OIL PUMP PRESSURE RELIEF VALVE . . . . . . 29
OIL FILTER ADAPTER . . . . . . . . . . . . . . . . . . . 29
PISTONS AND CONNECTING ROD
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CYLINDER WALL LINER ASSEMBLY . . . . . . . . 33
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . 35
ENGINE MOUNTSFRONT . . . . . . . . . . . . . . . 14
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . 15
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 38
CLEANING AND INSPECTION
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 38
ROCKER ARMS AND PUSH RODS . . . . . . . . . 39
PISTONS AND CONNECTING ROD
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CYLINDER WALL LINER ASSEMBLY . . . . . . . . 40
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPECIFICATIONS
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . 42
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 44
SPECIAL TOOLS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 45
GENERAL INFORMATION
ENGINE IDENTIFICATION
The engi ne model code (3-di gi t number/l etter code)
and seri al number are stamped on the forward faci ng
si de of the engi ne bl ock (Fi g. 1).
Fig. 1 Engine Code Location
ZG ENGINE 9 - 1
HYDRAULIC TAPPETS
Before di sassembl i ng any part of the engi ne to cor-
rect tappet noi se, check the oi l pressure. I f vehi cl e
has no oi l pressure gauge, i nstal l a rel i abl e gauge at
the pressure sendi ng uni t. The pressure shoul d be
between 4 bars (50 psi ) at 3000 RPM.
Check the oi l l evel after the engi ne reaches normal
operati ng temperature. Al l ow 5 mi nutes to stabi l i ze
oi l l evel , check di psti ck. The oi l l evel i n the pan
shoul d never be above the FULL mark or bel ow the
ADD OI L mark on di psti ck. Ei ther of these 2 condi -
ti ons coul d be responsi bl e for noi sy tappets:
OIL LEVEL HIGH
I f oi l l evel i s above the FULL mark, i t i s possi bl e
for the connecti ng rods to di p i nto the oi l . Wi th the
engi ne runni ng, thi s condi ti on coul d create foam i n
the oi l pan. Foam i n oi l pan woul d be fed to the
hydraul i c tappets by the oi l pump causi ng them to
l ose l ength and al l ow val ves to seat noi si l y.
OIL LEVEL LOW
Low oi l l evel may al l ow oi l pump to take i n ai r.
When ai r i s fed to the tappets, they l ose l ength whi ch
al l ows val ves to seat noi si l y. Any l eaks on i ntake si de
of oi l pump through whi ch ai r can be drawn wi l l cre-
ate the same tappet acti on. Check the l ubri cati on
system from the i ntake strai ner to the pump cover,
i ncl udi ng the rel i ef val ve retai ner cap. When tappet
noi se i s due to aerati on, i t may be i ntermi ttent or
constant, and usual l y more than 1 tappet wi l l be
noi sy. When oi l l evel and l eaks have been corrected,
operate the engi ne at fast i dl e. Run engi ne for a suf-
fi ci ent ti me to al l ow al l of the ai r i nsi de the tappets
to be bl ed out.
DESCRIPTION AND OPERATION
LUBRICATION SYSTEM
The pressuri zed system uses a rotary pump (3)
l ocated i n the front of the engi ne bl ock, dri ven by a
gear whi ch meshes di rectl y wi th the crankshaft gear.
Al l the oi l sent to every l ubri cated part i s fi l tered.
The pump sends the oi l through a pressure rel i ef
val ve (2) to the fi l ter (7) and through gal l eri es i n the
crankcase to the crankshaft beari ngs (8), camshaft
beari ngs (11) and turbocharger (10). The pi ston pi ns,
connecti ng rod smal l ends and i nsi des of the pi stons
are l ubri cated and cool ed by oi l sprayed out from jets
(9) i n the crankshaft mounti ng bl ocks. The l ubri cat-
i ng oi l i s sent to the rockers (12) through an external
pi pe. A val ve i n the fi l ter cartri dge enabl es the oi l to
be ci rcul ated even when the cartri dge i s cl ogged.
Sump i nl et (1). Pressure rel i ef val ve (2). Oi l pump
(3). Oi l cool er (6). Fi l ter cartri dge (7). Crankshaft
beari ngs (8). Jet val ve (9). Turbocharger beari ngs
(10). Camshaft beari ngs (11). Rockers (12). Engine Description
Fig. 2 Lubrication Lines
9 - 2 ENGINE ZG
GENERAL INFORMATION (Continued)
DIAGNOSIS AND TESTING
SERVICE DIAGNOSISDIESELPERFORMANCE
ZG ENGINE 9 - 3
9 - 4 ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
ZG ENGINE 9 - 5
DIAGNOSIS AND TESTING (Continued)
9 - 6 ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
ZG ENGINE 9 - 7
DIAGNOSIS AND TESTING (Continued)
9 - 8 ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
SERVICE DIAGNOSISDIESELMECHANICAL.
ZG ENGINE 9 - 9
DIAGNOSIS AND TESTING (Continued)
9 - 10 ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
ZG ENGINE 9 - 11
DIAGNOSIS AND TESTING (Continued)
TAPPET NOISE
(1) To determi ne source of tappet noi se, operate
engi ne at i dl e wi th cyl i nder head covers removed.
(2) Feel each val ve spri ng or rocker arm to detect
noi sy tappet. The noi sy tappet wi l l cause the affected
spri ng and/or rocker arm to vi brate or feel rough i n
operati on.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Val ve tappet noi se ranges from l i ght noi se to a
heavy cl i ck. A l i ght noi se i s usual l y caused by exces-
si ve l eak down around the uni t pl unger or by the
pl unger parti al l y sti cki ng i n the tappet body cyl i nder.
The tappet shoul d be repl aced. A heavy cl i ck i s
caused by a tappet check val ve not seati ng or by for-
ei gn parti cl es becomi ng wedged between the pl unger
and the tappet body. Thi s wi l l cause the pl unger to
sti ck i n the down posi ti on. Thi s heavy cl i ck wi l l beac-
compani ed by excessi ve cl earance between the val ve
stem and rocker arm as val ve cl oses. I n ei ther case,
tappet assembl y shoul d be removed for i nspecti on
and cl eani ng.
The val ve trai n generates a noi se very much l i ke a
l i ght tappet noi se duri ng normal operati on. Care
must be taken to ensure that tappets are maki ng the
noi se. I n general , i f more than one tappet seems to
be noi sy, i ts probabl y not the tappets.
SERVICE PROCEDURES
VALVE SERVICE
Thi s procedure i s done wi th the engi ne cyl i nder
head removed from the bl ock.
DISASSEMBLY
(1) Remove the engi ne cyl i nder head from the cyl -
i nder bl ock (refer to cyl i nder head removal i n thi s
secti on).
(2) Use Val ve Spri ng Compressor Tool and com-
press each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, and spri ngs.
(4) Use an Arkansas smooth stone or a jewel ers
fi l e to remove any burrs on the top of the val ve stem,
especi al l y around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
the same order as removed.
VALVE CLEANING
(1) Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
(2) Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
INSPECTION
(1) I nspect for cracks i n the combusti on chambers
and val ve ports.
(2) I nspect for cracks on the exhaust seat.
(3) I nspect for cracks i n the gasket surface at each
cool ant passage.
(4) I nspect val ves for burned, cracked or warped
heads.
(5) I nspect for scuffed or bent val ve stems.
(6) Repl ace val ves di spl ayi ng any damage.
(7) Check val ve spri ng hei ght (Fi g. 3).
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 4.52-4.49
mm (.178-.177 i nch) must remai n (Fi g. 4). I f the mar-
gi n i s l ess than 4.49 mm (.177 i nch), the val ve must
be repl aced.
Fig. 3 Valve Spring Chart
9 - 12 ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
VALVE STAND DOWN
Val ve stand down i s to mai ntai n the adequate com-
pressi on rati o.
(1) I nvert cyl i nder head.
(2) Fi t each val ve to i ts respecti ve val ve gui de.
(3) Usi ng a strai ght edge and feel er gauge (Fi g. 5),
check val ve head stand down: I nl et val ve head stand
down .80 to 1.2 mm (.031 to .047 i n.) and exhaust
val ve stand down .79 to 1.19 mm (.031 to .047 i n).
(4) I f val ve head stand down i s not i n accordance
wi th above, di scard ori gi nal val ves, check stand down
wi th new val ves and recut val ve seat i nserts to
obtai n correct stand down.
VALVE GUIDES
(1) Val ve Gui des hei ght requi rement.
(2) Measurement A (Fi g. 6): 13.50 - 14.00 mm.
Fig. 4 Valve Specification
Fig. 5 Checking Valve Stand Down
Fig. 6 Valve Guide Height
ZG ENGINE 9 - 13
SERVICE PROCEDURES (Continued)
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record i nternal di ameter of val ve
gui des. Val ve gui de i nternal di ameter i s 8.0 to 8.015
mm (.3149 to .3155 i ns.).
(2) Measure val ve stems and record di ameters.
I ntake val ve stem di ameter 7.94 to 7.96 mm (.3125 to
.3133 i n). Exhaust val ve stem di ameter 7.92 to 7.94
mm (.3118 to .31215 i n).
(3) Subtract di ameter of val ve stem from i nternal
di ameter of i ts respecti ve val ve gui de to obtai n val ve
stem cl earance i n val ve gui de. Cl earance of i nl et
val ve stem i n val ve gui de i s .040 to .075 mm (.0015
to .0029 i n). Cl earance of exhaust val ve stem i n val ve
gui de i s .060 to .095 mm (.0023 to .0037 i n).
(4) I f val ve stem cl earance i n val ve gui de exceeds
tol erances, new val ve gui des must be i nstal l ed.
REMOVAL AND INSTALLATION
ENGINE MOUNTSFRONT
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
REMOVALRIGHT SIDE
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Support the engi ne.
(4) Remove through bol t nut. DO NOT remove the
through bol t (Fi g. 7).
(5) Remove i nsul ator si l l pl ate bol ts.
(6) Remove engi ne mount bracket bol ts.
(7) Rai se engi ne up.
(8) Remove the through bol t.
(9) Remove i nsul ator.
(10) Remove engi ne bracket.
INSTALLATIONRIGHT SIDE
(1) I nstal l the engi ne support bracket and bol ts,
ti ghten bol ts to 61 Nm (45 ft. l bs.).
(2) Secure the i nsul ator assembl y on the l ower si l l .
Ti ghten the bol ts to 65 Nm (48 ft. l bs.).
(3) Lower engi ne and pl ace the i nsul ator assembl y
i nto the bracket.
(4) I nstal l the through bol t nut. Ti ghten the
through bol t nut to 65 Nm (48 ft. l bs.).
(5) Remove the engi ne support.
(6) Lower the vehi cl e.
(7) Connect negati ve cabl e to battery
REMOVALLEFT SIDE
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e.
(3) Support the engi ne.
(4) Remove through bol t nut. DO NOT remove the
through bol t (Fi g. 8).
(5) Remove i nsul ator si l l pl ate bol ts.
(6) Remove engi ne mount bracket bol ts.
(7) Rai se engi ne up.
(8) Remove the through bol t.
(9) Remove i nsul ator.
(10) Remove engi ne bracket.
INSTALLATIONLEFT SIDE
(1) I nstal l the engi ne support bracket and bol ts,
ti ghten bol ts to 61 Nm (45 ft. l bs.).
(2) Secure the i nsul ator assembl y on the l ower si l l .
Ti ghten the bol ts to 65 Nm (48 ft. l bs.).
(3) Lower engi ne and pl ace the i nsul ator assembl y
i nto the bracket.
(4) I nstal l the through bol t nut. Ti ghten the
through bol t nut to 65 Nm (48 ft. l bs.).
(5) Remove the engi ne support.
(6) Lower the vehi cl e.
(7) Connect negati ve cabl e to battery
Fig. 7 Front MountRight Side
Fig. 8 Front MountLeft Side
9 - 14 ENGINE ZG
SERVICE PROCEDURES (Continued)
ENGINE MOUNTREAR
A resi l i ent rubber cushi on supports the transmi s-
si on at the rear between the transmi ssi on extensi on
housi ng and the rear support crossmember or ski d
pl ate.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the bracket (Fi g. 9). Remove the crossmember.
(a) Remove the support cushi on nuts and
remove the cushi on.
(b) I f necessary, remove the bol ts hol di ng the
transmi ssi on support bracket to the transmi ssi on.
Remove the bracket.
INSTALLATION
(1) I f removed, posi ti on the transmi ssi on support
bracket to the transmi ssi on and i nstal l the bol ts.
Ti ghten the bol ts to 46 Nm (34 ft. l bs.) torque.
(2) Posi ti on the support cushi on onto the transmi s-
si on support crossmenber. Ti ghten the nuts to 54
Nm (40 ft. l bs.) torque.
(3) I nstal l crossmember.
(4) Secure support cushi on to bracket. Ti ghten the
nuts to 54 Nm (40 ft. l bs.) torque.
(5) Remove transmi ssi on support and l ower vehi cl e.
(6) Connect negati ve battery cabl e.
ENGINE ASSEMBLY
REMOVAL
(1) Di sconnect the battery cabl es. Remove the bat-
tery.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Di sconnect
the engi ne compartment l amp wi ri ng connecti on.
Remove the hood.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(3) Drai n the cool i ng system (refer to Group 7,
Cool i ng).
(4) Di scharge the ai r condi ti oni ng system, i f
equi pped (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng for servi ce procedures).
(5) Remove the l ower radi ator hose.
(6) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 10).
(7) Remove upper crossmember, refer to Group 23,
Body Components for procedure.
(8) Remove ai r cl eaner hose from turbocharger and
breather hose.
(9) Remove the ai r cl eaner assembl y.
(10) Di sconnect A/C l i nes from condenser (Refer to
Group 24, Heati ng and Ai r Condi ti oni ng) cap l i nes to
keep forei gn parti cl es out.
Fig. 9 Rear Mount
Fig. 10 Right side of Engine
ZG ENGINE 9 - 15
REMOVAL AND INSTALLATION (Continued)
(11) Ti p radi ator, A/C condenser, and fan shroud
assembl y away from engi ne.
(12) Remove fan and set fan i nsi de fan shroud.
(13) Remove fan, fan shroud, radi ator, and A/C
condenser as an assembl y.
(14) Di sconnect the heater hoses and cool ant
recovery bottl e hose (Fi g. 10).
(15) Remove fuel l i nes, fuel fi l ter, refer to Group
14, Fuel Systems.
(16) I f equi pped wi th ai r condi ti oni ng, remove the
servi ce val ves and cap the compressor ports (refer to
Group 14, Fuel System).
(17) Remove the power brake vacuum check val ve
from the booster, i f equi pped.
(18) I f equi pped wi th power steeri ng (Fi g. 11):
(a) Di sconnect the power steeri ng pressure hoses
from the steeri ng gear.
(b) Di sconnect return l i ne from reservoi r and
drai n the pump reservoi r.
(c) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn materi al from enteri ng the
system.
(19) I denti fy, tag and di sconnect al l necessary wi re
connectors and vacuum hoses.
(20) Remove gear shi ft l evers (refer to Group 21,
Transmi ssi ons).
(21) Rai se and support the vehi cl e.
(22) Remove Prop shafts (refer to Group 2, Sus-
pensi on and Dri veshafts).
(23) Di sconnect the exhaust pi pe from the exhaust
down mani fol d (refer to Group 11, Exhaust system
and I ntake Mani fol ds).
(24) Remove rear crossmember and transmi ssi on
mount, support transmi ssi on.
(25) Ti p transmi ssi on to remove four bol ts on top
of transmi ssi on to engi ne bl ock. Di sconnect wi ri ng
from transmi ssi on.
(26) Support transmi ssi on, remove l ower bol ts and
brackets, remove transmi ssi on.
(27) Remove the engi ne support cushi on-to-engi ne
compartment bracket nuts.
(28) Lower the vehi cl e.
(29) Attach a l i fti ng devi ce to the engi ne.
(30) Li ft the engi ne out of the engi ne compart-
ment. I nstal l the engi ne on an engi ne stand.
INSTALLATION
(1) Li ft the engi ne off the stand and l ower i t i nto
the engi ne compartment.
(2) I nstal l the engi ne support cushi ons (i f
removed).
(3) Lower the engi ne and engi ne support cushi ons
onto the engi ne compartment brackets.
(4) Rai se the vehi cl e.
(5) I nstal l transmi ssi on to engi ne refer to Group
21, transmi ssi ons.
(6) Support transmi ssi on.
(7) Remove the engi ne l i fti ng devi ce.
(8) I nstal l rear crossmember ti ghten bol ts to 42
Nm (31 ft. l bs.)
(9) I nstal l transmi ssi on rear mount, for procedure
refer to Engi ne MountRear i n thi s secti on.
(10) Ti ghten the engi ne support cushi on through-
bol t nuts 65 Nm (48 ft. l bs.).
(11) I nstal l the exhaust pi pe support.
(12) Connect the exhaust down pi pe to the exhaust
system refer to Group 11, Exhaust System and
I ntake Mani fol d.
Fig. 11 Power Steering Lines
Fig. 12 Left Side of Engine
9 - 16 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(13) Lower the vehi cl e.
(14) Connect al l the vacuum hoses and wi re con-
nectors.
(15) I f equi pped wi th power steeri ng:
(a) Remove the protecti ve caps
(b) Connect the pressure hoses to the steeri ng
gear. Ti ghten the nut to 28 Nm (21 ft. l bs.).
(c) Connect return l i ne from reservoi r to the
pump.
(d) Fi l l the pump reservoi r wi th fl ui d.
(16) Connect the servi ce val ves to the A/C com-
pressor ports, i f equi pped wi th ai r condi ti oni ng.
(17) I nstal l fuel fi l ter and bracket. Ti ghten bol ts to
28 Nm (250 i n. l bs.)
(18) Connect the fuel suppl y and return l i nes
(19) Connect brake booster hose.
(20) Connect the heater hoses and recovery bottl e
hose.
(21) Connect charge ai r cool er hoses to turbo and
i ntake mani fol d.
(22) I nstal l the fan, fan shroud and radi ator/con-
denser (i f equi pped wi th ai r condi ti oni ng).
(23) I nstal l fan, ti ghten to 56 Nm (41 ft. l bs.).
(24) Connect the upper and l ower radi ator hoses.
(25) I nstal l upper crossmember, refer to Group 23,
Body Components.
(26) I nstal l ai r cl eaner and bracket.
(27) Connect ai r cl eaner hose to turbo and connect
breather hose.
(28) I nstal l battery tray and battery.
(29) Connect the battery cabl es.
(30) Fi l l the cool i ng system.
(31) I f equi pped, I f system was opened, evacuate
and charge the ai r condi ti oni ng system (refer to
Group 24, Heater and Ai r Condi ti oni ng).
(32) I nstal l the hood.
(33) I nstal l the ai r cl eaner.
(34) Start the engi ne and i nspect for l eaks.
(35) Stop the engi ne and check the fl ui d l evel s.
Add fl ui d, as requi red.
CYLINDER HEAD COVER
REMOVAL
(1) Di sconnect the battery cabl e.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool i ng system (refer to Group 7,
Cool i ng).
(3) Di scharge the ai r condi ti oni ng system, i f
equi pped (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng for servi ce procedures).
(4) I f equi pped wi th ai r condi ti oni ng, remove the
A/C l i nes at the compressor and cap (refer to Group
24, Heati ng and Ai r Condi ti oni ng). Remove A/C l i ne
bracket attached to cyl i nder head cover, and move
A/C l i nes away from cyl i nder head.
(5) Remove generator support brace (Fi g. 13).
(6) Remove Crankcase breather hose from rear of
the val ve cover
(7) Remove the upper radi ator hose and cool ant
tank hose.
(8) Remove water mani fol d.
(9) Loosen cyl i nder head cover bol ts and rai se cyl -
i nder head cover.
(10) Rai se vehi cl e on hoi st.
(11) Support transmi ssi on wi th a sui tabl e jack.
(12) Remove l ower attachi ng bol t.
(13) Remove enti re crossmember.
(14) Take the l owest brake l i ne on dash out of al l
the mounti ng cl i ps (RHD Vehi cl es onl y).
(15) Lower the enti re transmi ssi on and transfer
case assembl y approxi matel y 130 mm.
WARNING: Ensure the transmission and transfer
case are adequately supported.
(16) Remove the engi ne cyl i nder head cover.
INSTALLATION
(1) Posi ti on val ve cover on cyl i nder heads.
(2) Rai se the enti re transmi ssi on and transfer case
assembl y approxi matel y 130 mm.
(3) Rei nstal l the l owest brake l i ne on dash i nto al l
the mounti ng cl i ps (RHD Vehi cl es onl y).
(4) I nstal l the enti re crossmember.
(5) I nstal l the l ower attachi ng bol t.
(6) I nstal l transmi ssi on support.
Fig. 13 Generator Brace
ZG ENGINE 9 - 17
REMOVAL AND INSTALLATION (Continued)
(7) Lower vehi cl e.
(8) I nstal l val ve cover, ti ghten nuts to 19 Nm (168
i n. l bs.).
(9) Connect crankcase breather hose.
(10) I nstal l water mani fol d and ti ghten bol ts to 12
Nm (106 i n. l bs.).
(11) I nstal l generator support brace.
(12) Connect cool ant tank hose to water mani fol d.
(13) Connect the upper radi ator hose.
(14) Connect the A/C l i nes to compressor and
i nstal l bracket on cyl i nder head cover, i f equi pped
wi th ai r condi ti oni ng.
(15) Connect negati ve cabl e to battery.
(16) I f equi pped wi th A/C, evacuate and charge the
ai r condi ti oni ng system (refer to Group 24, Heater
and Ai r Condi ti oni ng).
(17) Fi l l the cool i ng system. Check for l eaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(18) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the thermostat opens. Add cool ant, i f requi red.
HYDRAULIC TAPPETS
REMOVAL
(1) Remove the ai r cl eaner.
(2) Remove cyl i nder head cover (refer to cyl i nder
val ve cover removal i n thi s secti on).
(3) Remove rocker assembl y and push rods (Fi g.
14). I denti fy push rods to ensure i nstal l ati on i n ori g-
i nal l ocati on.
(4) Remove cyl i nder head, i ntake mani fol d, and
exhaust mani fol d, refer to cyl i nder head removal i n
thi s secti on.
(5) Remove yoke retai ner and al i gni ng yokes (Fi g.
15).
(6) Sl i de Hydraul i c Tappet Remover/I nstal l er Tool
through openi ng i n bl ock and seat tool fi rml y i n the
head of tappet.
(7) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed, i denti fy tappets to
ensure i nstal l ati on i n ori gi nal l ocati on.
(8) I f the tappet or bore i n cyl i nder bl ock i s scored,
scuffed, or shows si gns of sti cki ng, ream the bore to
next oversi ze. Repl ace wi th oversi ze tappet.
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT dis-
assemble a tappet on a dirty work bench.
INSTALLATION
(1) Lubri cate tappets.
(2) I nstal l tappets and yoke retai ners i n thei r ori g-
i nal posi ti ons. Ensure that the oi l feed hol e i n the
si de of the tappet body faces up (away from the
crankshaft).
(3) I nstal l cyl i nder head, i ntake mani fol d, and
exhaust mani fol d, refer to cyl i nder head i nstal l ati on
i n thi s secti on.
(4) I nstal l push rods i n ori gi nal posi ti ons.
Fig. 14 Tappet And Rocker Arm Assembly
Fig. 15 Tappet And Yoke
9 - 18 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(5) I nstal l rocker arms (refer to rocker arms i n thi s
secti on).
(6) I nstal l cyl i nder head cover (refer to cyl i nder
val ve cover i nstal l ati on i n thi s secti on).
(7) Start and operate engi ne. Warm up to normal
operati ng temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Di sconnect the battery cabl es.
(2) Di scharge the ai r condi ti oni ng system, i f
equi pped (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng for servi ce procedures).
(3) I f equi pped wi th ai r condi ti oni ng, remove the
servi ce val ves and cap the compressor ports (refer to
Group 24, Heati ng and Ai r Condi ti oni ng).
(4) Remove generator bracket.
(5) Remove breather hose.
(6) Remove cyl i nder head cover.
(7) Remove rocker retai ni ng nut (Fi g. 16).
(8) Remove rocker assembl y. Pl ace them on a
bench i n the same order as removed.
(9) Remove the push rods and pl ace them on a
bench i n the same order as removed.
INSTALLATION
(1) Rotate the crankshaft unti l the mark l i nes up
wi th the TDC mark on the ti mi ng cover.
(2) I nstal l the push rods i n the same order as
removed.
(3) I nstal l rocker arm assembl i es i n the same
order as removed. Ti ghten the rocker arm nuts to
29.4 Nm (264 i n. l bs.) torque.
(4) I nstal l cyl i nder head cover, torque nuts to 19
Nm (168 i n. l bs.).
(5) I nstal l breather hose.
(6) I nstal l generator bracket, ti ghten bol ts to 7
Nm (4 ft. l bs.).
(7) Connect the servi ce val ves to the A/C compres-
sor ports, i f equi pped wi th ai r condi ti oni ng.
(8) I f equi pped, evacuate and charge the ai r condi -
ti oni ng system (refer to Group 24, Heater and Ai r
Condi ti oni ng).
(9) Connect battery cabl e.
VALVE SPRINGS
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(1) Remove the engi ne cyl i nder head cover, refer to
cyl i nder head cover removal i n thi s secti on.
(2) Remove rocker arms assembl i es for access to
each val ve spri ng to be removed.
(3) Remove push rods. Retai n the push rods, and
rocker arms assembl i es i n the same order and posi -
ti on as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) I nstal l an ai r hose adaptor i n the fuel i njector
hol e.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool to compress the spri ng and remove
the l ocks.
(8) Remove val ve spri ng and retai ner.
(9) I nspect the val ve stems, especi al l y the grooves.
An Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
Fig. 16 Rocker Arm Retaining Nut
ZG ENGINE 9 - 19
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l val ve spri ng and retai ner.
(2) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool and i nsert the val ve l ocks. Rel ease
the spri ng tensi on and remove the tool . Tap the
spri ng from si de-to-si de to ensure that the spri ng i s
seated properl y on the engi ne cyl i nder head.
(3) Di sconnect the ai r hose. Remove the adaptor
from the fuel i njector hol e and i nstal l the fuel i njec-
tor.
(4) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(5) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(6) I nstal l the rocker arm assembl i es, at thei r ori g-
i nal l ocati on.
(7) Ti ghten the rocker arm assembl y nut to 35
Nm (26 ft. l bs.) torque.
(8) I nstal l the engi ne cyl i nder head cover, refer to
cyl i nder head cover i nstal l ati on i n thi s secti on.
ENGINE CYLINDER HEAD
REMOVAL
(1) Di sconnect the battery cabl e.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool i ng system (refer to Group 7,
Cool i ng).
(3) Di scharge the ai r condi ti oni ng system, i f
equi pped (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng for servi ce procedures).
(4) I f equi pped wi th ai r condi ti oni ng, remove the
A/C l i nes at the compressor and cap (refer to Group
24, Heati ng and Ai r Condi ti oni ng). Remove A/C l i ne
bracket attached to cyl i nder head cover, and move
A/C l i nes away from cyl i nder head.
(5) Remove ai r cl eaner hose from turbocharger and
breather hose.
(6) Remove the ai r cl eaner assembl y and breather
hose.
(7) Remove generator support bracket.
(8) Loosen cyl i nder head cover bol ts.
(9) Rai se vehi cl e on hoi st.
(10) Remove transmi ssi on crossmember bol ts, and
l ower rear of engi ne.
(11) Remove the upper radi ator hose and cool ant
recovery hose.
(12) Remove water mani fol d and recovery hose.
(13) Di sconnect the heater hoses and cool ant
recover bottl e hose.
(14) Di sconnect EGR tube from EGR val ve.
(15) Remove EGR val ve
(16) Remove exhaust heat shi el d from exhaust
mani fol d.
(17) Remove exhaust heat shi el d from down pi pe.
(18) Remove exhaust down pi pe from turbocharger
(Fi g. 17).
(19) Di sconnect oi l feed l i ne from turbocharger.
(20) Di sconnect oi l drai n l i ne from turbocharger.
(21) Remove Exhaust mani fol d (refer to Group 11,
Exhaust System and I ntake Mani fol d).
(22) Remove I ntake mani fol d (refer to Group 11,
Exhaust System and I ntake Mani fol d).
(23) Remove oi l feed l i ne for rocker arm assembl i es
(Fi g. 18).
Fig. 17 Turbocharger
Fig. 18 Rocker Arm Oil Feed Lines
9 - 20 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(24) Remove Crankcase breather hose from rear of
the val ve cover
(25) Remove the i njector sensor wi re and the gl ow
pl ug hot l ead.
(26) Remove fuel l i nes, fuel fi l ter, refer to Group
14, Fuel Systems.
(27) Remove i njector fuel l i nes from i njectors to
pump.
(28) Remove fuel i njectors wi th tool VM-1012A
(Fi g. 19) (refer to Group 14, Fuel System).
(29) Remove the engi ne cyl i nder head cover.
(30) Remove rocker retai ni ng nuts (Fi g. 21).
(31) Remove rocker assembl y. Pl ace them on a
bench i n the same order as removed.
(32) Remove the push rods and pl ace them on a
bench i n the same order as removed.
(33) Mark cyl i nder head posi ti ons.
(34) Remove the engi ne cyl i nder head bol ts wi th
speci al tool VM-1018 and VM-1019.
(35) Remove the engi ne cyl i nder head and gasket.
(36) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
CYLINDER HEAD GASKETS
A steel cyl i nder head gasket i s used for al l four cyl -
i nder heads.
Cyl i nder head gaskets are avai l abl e i n three thi ck-
nesses. I denti fi cati on hol es i n the ri ght front corner
of the gasket i ndi cate the thi ckness of the gasket
(Fi g. 22).
Fig. 19 Fuel Injector Tool VM-1012A
Fig. 20 Fuel Injector
Fig. 21 Rocker Arm Retaining Nuts
ZG ENGINE 9 - 21
REMOVAL AND INSTALLATION (Continued)
CAUTION: Piston protrusion must be measured, to
determine cylinder head gasket thickness, if one or
more cylinder wall liners have been replaced.
NOTE: If cylinder wall liners have not been
removed; the same thickness head gasket removed,
may be used.
MEASURING PISTON PROTRUSION
(1) Use speci al tool VM-1010 wi th di al i ndi cator
speci al tool VM-1013 (Fi g. 23).
(2) Bri ng the pi ston of cyl i nder no. 1 exactl y to top
dead center.
(3) Zero the di al i ndi cator on the cyl i nder bl ock
mati ng surface.
(4) Setup the di al i ndi cator on the pi ston crown
(above the center of the pi ston pi n) 5mm (1/8 i n.)
from the edge of the pi ston and note the measure-
ment (Fi g. 24).
(5) Repeat the procedure wi th the rest of the cyl -
i nders.
(6) Establ i sh the thi ckness of the steel gasket for
al l four cyl i nder heads on the basi s of the greatest
pi ston protrusi on (Fi g. 22).
CAUTION: Gaskets are to be installed DRY. DO NOT
use a gasket sealing compound on the gasket.
INSTALLATION
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) I nstal l cyl i nder head al i gnment studs
(VM-1009).
(3) After determi ni ng the correct head gasket
thi ckness, cl ean the bl ock and head mati ng surfaces,
pl ace the engi ne cyl i nder head gasket over the dow-
el s.
(4) Pl ace the engi ne cyl i nder head over the dowel s.
CAUTION: New cylinder head bolts should be used.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
25):
(a) The threads and undersi de heads of the bol ts
shoul d be l ubri cated. Use the cyl i nder head al i gn-
ment studs tool number VM-1009. Posi ti on the
heads on the bl ock and secure wi th the ten l arge
center bol ts and spacers (cl amps), fi nger ti ght onl y.
Be sure that the vari ous cl amps are i nstal l ed cor-
rectl y and the head gaskets remai n i n thei r proper
Fig. 22 Steel Type Cylinder Head Gasket
identification
Fig. 23 Measuring Piston Protrusion
Fig. 24 Piston Protrusion Chart
9 - 22 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
posi ti on, compl etel y covered. Then, l ubri cate and
i nstal l the ei ght smal l bol ts, al so fi nger ti ght.
(6) Hand ti ghten oi l feed l i ne for rocker arm
assembl i es
(7) I nstal l the i ntake and exhaust mani fol ds wi th
new gaskets, parti al l y ti ghteni ng the nuts to a max-
i mum of 5 Nm (44 i n. l bs.). Thi s wi l l al i gn the heads
(refer to Group 11, Exhaust System and I ntake Man-
i fol d for the proper procedures).
(8) Then, ti ghten the 12mm bol ts wi th speci al tool
VM-1019 i n the fol l owi ng manner:
1st Phase: Head Bol ts Ti ghteni ng -- (Fi g. 25)
Central bol ts (A-L): Ti ghten al l bol ts, starti ng wi th
bol t A then B-C-D-E-F-G-H-I -L, to 30 Nm. Repeat
the operati on wi th the same torque. Fol l owi ng the
same sequence rotate each bol t through an angl e of
70 usi ng angl e torque tool . Then rotate the bol ts an
addi ti onal 70 fol l owi ng ti ghteni ng sequence.
(9) Then, ti ghten the 14mm bol ts wi th speci al tool
VM-1018 i n the fol l owi ng manner:
Si de bol ts (M1-M2): Ti ghten M1 bol ts to 30 Nm,
then rotate them 85(+/-5). Ti ghten M2 bol ts to 30
Nm, then rotate them 85(+/-5).
NOTE: If vehicle is equipped with A/C do not install
A/C lines to compressor and charge A/C till Phase 2
is complete.
(10) 2nd Phase: After 20 mi nutes of engi ne opera-
ti on at operati ng temperature, al l ow engi ne to cool
down compl etel y. Then re-torque the head bol ts as
fol l ows:
Central bol ts A-L: Starti ng from bol t A, sl acken
and re-torque i t i mmedi atel y to 30 Nm + 65. Rotate
the bol t an addi ti onal 65. Then proceed i n the same
way, bol t by bol t, fol l owi ng al phabeti cal order, as
i ndi cated.
Si de bol ts M1-M2: Without slackening , torque
bol ts M1 then bol ts M2 to 90 Nm (66 ft. l bs.).
(11) Ti ghten i ntake nuts to 30 Nm (22 ft. l bs.) and
exhaust mani fol ds nuts to 30 Nm (22 ft. l bs.) speci -
fi ed torque after compl eti ng Phase 2.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(12) Ti ghten oi l feed l i nes for rocker arm assem-
bl i es to 13 Nm (112 i n. l bs.).
(13) I nstal l push rods and rocker arm assembl i es,
ti ghten nut to 35 Nm (26 ft. l bs.).
(14) I nstal l val ve cover, ti ghten nuts to 19 Nm
(168 i n. l bs.).
(15) Connect crankcase breather hose.
(16) Connect the i njector sensor wi re and the gl ow
pl ug hot l ead.
(17) I nstal l turbocharger oi l feed l i ne, ti ghten
banjo bol ts to 27 Nm (20 ft. l bs), and i nstal l oi l drai n
l i ne to turbocharger.
(18) I nstal l water mani fol d and ti ghten bol ts to 12
Nm (106 i n. l bs.).
(19) I nstal l generator support bracket.
(20) Rai se vehi cl e on hoi st.
Fig. 25 Engine Cylinder Head Bolt Tightening Sequence
ZG ENGINE 9 - 23
REMOVAL AND INSTALLATION (Continued)
(21) I nstal l transmi ssi on crossmember bol ts
(22) I nstal l exhaust down pi pe to turbocharger,
ti ghten bol ts to 22 Nm (16 ft. l bs.).
(23) I nstal l exhaust down pi pe heat shi el d.
(24) I nstal l exhaust heat shi el d, Ti ghten bol ts to
11 Nm (8 ft. l bs.).
(25) I nstal l EGR val ve to i ntake mani fol d, ti ghten
bol ts to 26 Nm (19 ft. l bs.).
(26) I nstal l EGR tube to EGR val ve, ti ghten bol ts
to 26 Nm (19 ft. l bs.).
(27) I nstal l l ower Charge ai r cool er hose to turbo-
charger.
(28) I nstal l ai r cl eaner assembl y and hose.
(29) I nstal l oi l breather hose to ai r cl eaner hose.
(30) I nstal l upper charge cool er hose to turbo-
charger.
(31) Connect recover bottl e hose to water mani fol d.
(32) I nstal l fuel i njectors use tool VM-1012 (refer
to Group 14, Fuel System).
(33) I nstal l fuel i njector l i nes from the pump to
i njectors, ti ghten nuts to 23 Nm (17 ft. l bs.).
(34) Connect the A/C l i nes to compressor and
i nstal l bracket on cyl i nder head cover, i f equi pped
wi th ai r condi ti oni ng.
(35) I nstal l fuel fi l ter, Ti ghten bol ts to 28 Nm (250
i n. l bs.)
(36) Connect the fuel suppl y and return l i nes
(37) Connect the upper radi ator hose.
(38) Connect negati ve cabl e to battery.
(39) I f equi pped wi th A/C, evacuate and charge the
ai r condi ti oni ng system (refer to Group 24, Heater
and Ai r Condi ti oni ng).
(40) Fi l l the cool i ng system. Check for l eaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(41) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the thermostat opens. Add cool ant, i f requi red.
CAUTION: After rebuild or cylinder head gasket
replacement, the cylinder head must be retorqued
within the first 20,000km. If individual fiber type
head gaskets were used.
NOTE: The one piece steel type head gasket does
not require, the above mentioned, retorque proce-
dure.
CYLINDER HEAD RE-TORQUE
Wi thi n the fi rst 20,000 km after rebui l d, retorque
the head bol ts as fol l ows: (Fi g. 25) Central bol ts A-L:
Wi thout sl ackeni ng the bol ts, fol l owi ng al phabeti cal
order ti ghten the bol ts through an angl e of 15. Si de
bol ts M1-M2: Wi thout sl ackeni ng, ti ghten M1 then
M2 bol ts through an angl e of 15.
VIBRATION DAMPER
REMOVAL
(1) Di sconnect the battery cabl e.
(2) Remove fan and set fan i nsi de fan shroud then
remove fan shroud and fan as an assembl y.
(3) Remove accessary dri ve bel t, (refer to Group 7,
Cool i ng).
(4) Remove vi brati on damper nut.
(5) I nstal l tool VM-1000-2 to remove vi brati on
damper (Fi g. 27).
INSTALLATION
(1) I nstal l vi brati on damper and al i gn wi th key
way.
(2) I nstal l vi brati on damper nut and ti ghten to 160
Nm (118 ft. l bs.).
(3) I nstal l accessary dri ve bel t (refer to Group 7,
Cool i ng).
(4) Connect the battery cabl e.
Fig. 26 Accessary Drive System
9 - 24 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
TIMING CASE COVER OIL SEAL
REMOVAL
(1) Di sconnect the battery cabl e.
(2) Remove vi brati on damper (refer to vi brati on
damper removal i n thi s secti on).
(3) Pry out seal .
INSTALLATION
Remove the oi l seal ri ng. The seati ng di ameter
must be 68.000 - 68.030 mm.
(1) I nstal l new seal usi ng speci al tool VM-1015.
(2) I nstal l vi brati on damper (refer to vi brati on
damper i nstal l ati on i n thi s secti on).
(3) Connect the battery cabl e.
TIMING CASE COVER
REMOVAL
(1) Di sconnect the battery cabl e.
(2) Remove fan and set fan i nsi de fan shroud then
remove fan shroud and fan as an assembl y.
(3) Remove accessary dri ve bel t, (refer to Group 7,
Cool i ng).
(4) Remove vi brati on damper nut.
(5) I nstal l tool VM-1000-2 to remove vi brati on
damper.
(6) Remove fan pul l ey.
(7) Remove i dl er pul l ey and bracket. I dl er pul l ey
bol t have l eft hand threads.
(8) Remove the automati c bel t tensi oner.
(9) Di sconnect the oi l drai n back hose from exter-
nal vacuum pump to ti mi ng cover.
(10) Remove Power steeri ng pul l ey.
(11) Remove cover.
INSTALLATION
(1) Be sure mati ng surfaces of chai n case cover
and cyl i nder bl ock are cl ean and free from burrs.
(2) Appl y a conti nuous 3 mm bead of Si l i cone
Seal er (Fi g. 29) to ti mi ng cover, i nstal l wi thi n 10
mi nutes, ti ghten 6mm bol ts to 10.3 Nm (91 i n. l bs)
and ti ghten 8mm bol ts to 26.2 Nm (19 ft. l bs.).
Fig. 27 Vibration Damper Removal With Tool
VM-1000-2
Fig. 28 Front Cover Seal
Fig. 29 Front Cover Sealer Location
ZG ENGINE 9 - 25
REMOVAL AND INSTALLATION (Continued)
(3) I nstal l Power steeri ng pul l ey, ti ghten to 130
Nm (96 ft. l bs.).
(4) Connect oi l drai n to cover.
(5) I nstal l automati c bel t tensi oner.
(6) I nstal l i dl er pul l ey bracket, ti ghten bol ts to 40
Nm (29 ft. l bs.).
(7) I nstal l i dl er pul l ey, bol t has l eft hand thread,
ti ghten to 65 Nm (48 ft. l bs.).
(8) I nstal l fan pul l ey, ti ghten bol ts to 56 Nm (41
ft. l bs.).
(9) I nstal l vi brati on damper al i gn wi th keyway.
(10) Ti ghten vi brati on damper nut to 160 Nm (118
ft. l bs.).
(11) I nstal l accessary dri ve bel t (refer to Group 7,
cool i ng for procedure).
(12) I nstal l fan and fan shroud (refer to Group 7,
Cool i ng for procedure).
(13) Connect battery cabl e.
CAMSHAFT
REMOVAL
(1) Di sconnect the battery cabl e.
(2) Remove val ve cover, refer to val ve cover
removal i n thi s secti on.
(3) Remove cyl i nder head (refer to cyl i nder head
removal i n thi s secti on).
(4) Remove rocker arms, push rods, and hydraul i c
tappets, refer to the respecti ve groups i n thi s secti on.
(5) Remove fan and set fan i nsi de fan shroud then
remove fan shroud and fan as an assembl y.
(6) Remove accessary dri ve bel t.
(7) Remove radi ator (refer to Group 7, Cool i ng).
(8) Remove A/C condenser (refer to Group 24,
Heati ng and Ai r Condi ti oni ng).
(9) Remove vi brati on damper, refer to vi brati on
damper removal i n thi s secti on.
(10) Remove power steeri ng pul l ey.
(11) Remove ti mi ng case cover, refer to ti mi ng case
cover removal i n thi s secti on.
(12) Unscrew fl ange bol ts and remove camshaft
(Fi g. 31).
THRUST PLATE INSPECTION
Check the thi ckness (Fi g. 32) of the pl ate at poi nts
a-b-c-d. I f the measurement i s not between 3.950 -
4.050 i t must be changed.
Fig. 30 Camshaft Assembly
Fig. 31 Camshaft Removal
Fig. 32 Camshaft Thrust Plate
9 - 26 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Coat the camshaft journal s wi th cl ean engi ne
oi l and careful l y i nstal l the camshaft compl ete wi th
thrust pl ate and gear. Ti ghten retai ni ng bol ts to 24
Nm ( 18 ft. l bs.) torque. Be sure to al i gn the ti mi ng
marks as shown (Fi g. 33).
(2) I nstal l hydraul i c tappets and retai ni ng yokes.
(3) I nstal l cyl i nder heads (refer to cyl i nder heads
i n thi s secti on).
(4) Push rods, and rocker arm assembl i es, refer to
the respecti ve secti ons.
(5) I nstal l val ve cover (refer to val ve cover i nstal -
l ati on i n thi s secti on).
(6) I nstal l Ti mi ng case cover (refer to the ti mi ng
case cover i nstal l ati on i n thi s secti on).
(7) I nstal l Vi brati on damper (refer to the vi brati on
i nstal l ati on i n thi s secti on).
(8) I nstal l the A/C condenser (refer to Group 24,
Heati ng and Ai r Condi ti oni ng).
(9) I nstal l radi ator (refer to group 7, Cool i ng).
(10) I nstal l fan and fan shroud, ti ghten fan to 56
Nm (41 ft. l bs.).
(11) I f equi pped, evacuate and charge the ai r con-
di ti oni ng system (refer to Group 24, Heater and Ai r
Condi ti oni ng).
(12) Fi l l the cool i ng system. Check for l eaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(13) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the thermostat opens. Add cool ant, i f requi red.
CAMSHAFT BEARINGS
Thi s procedure requi res that the engi ne i s removed
from the vehi cl e.
REMOVAL
(1) Wi th engi ne compl etel y di sassembl ed, remove
camshaft rear pl ate and o-ri ng.
(2) I nstal l proper si ze adapters and horseshoe wash-
ers (part of Camshaft Beari ng Remover/I nstal l er Tool )
at back of each beari ng shel l . Dri ve out beari ng shel l s.
INSTALLATION
(1) I nstal l new camshaft beari ngs wi th Camshaft
Beari ng Remover/I nstal l er Tool by sl i di ng the new
camshaft beari ng shel l over proper adapter.
(2) Posi ti on rear beari ng i n the tool . I nstal l horse-
shoe l ock and by reversi ng removal procedure, care-
ful l y dri ve beari ng shel l i nto pl ace.
(3) I nstal l remai ni ng beari ngs i n the same man-
ner. Beari ngs must be careful l y al i gned to bri ng oi l
hol es i nto ful l regi ster wi th oi l passages from the
mai n beari ng. I f the camshaft beari ng shel l oi l hol es
are not i n exact al i gnment, remove and i nstal l them
correctl y. I nstal l a new rear pl ate o-ri ng at the rear
of camshaft. Be sure this seal does not leak.
OIL PAN
REMOVAL
(1) Di sconnect battery cabl e.
(2) Rai se vehi cl e on hoi st.
(3) Drai n oi l .
(4) Remove oi l pan l ower bol ts on sump.
(5) Remove bol ts from l ower oi l pan. Remove the 4
bol ts that are on the i nsi de of the oi l pan.
(6) Remove oi l pan.
Fig. 33 Timing Marks
Fig. 34 Oil Pan
ZG ENGINE 9 - 27
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Remove al l gasket materi al from cyl i nder bl ock.
Be careful not gouge or scratch al umi num pan seal -
i ng surface.
(2) I nstal l oi l pan. Appl y a conti nuous 3 mm bead
of Si l i cone Seal er to oi l pan, i nstal l wi thi n 10 mi n-
utes.
(3) I nstal l i nsi de oi l pan bol ts and torque bol ts to
11 Nm (8 ft. l bs.).
(4) I nstal l l ower oi l pan bol ts and torque to 11 Nm
(8 ft. l bs.).
(5) I nstal l oi l drai n pl ug ti ghten to 79 Nm (58 ft.
l bs).
(6) Lower vehi cl e.
(7) Fi l l engi ne wi th proper amount of oi l .
(8) Connect battery cabl e.
OIL PUMP
REMOVAL
(1) Remove front cover, (refer to front cover
removal i n thi s secti on).
(2) Remove oi l pump (Fi g. 35).
INSTALLATION
(1) I nstal l new O-ri ng and l ubri cate wi th cl ean
engi ne oi l .
(2) I nstal l oi l pump and ti ghten retai ni ng screws
to 24.5-29.9 Nm (22.7-28.3 ft. l bs.). Check for normal
backl ash between pump and crankshaft gears.
(3) I nstal l front cover, refer to front cover i nstal l a-
ti on i n thi s secti on.
INTERNAL VACUUM PUMP
REMOVAL
(1) Remove the front cover refer to front cover
removal i n thi s secti on.
(2) Remove 4 bol ts.
(3) Remove i nternal vacuum pump. Vacuum gear
has a spri ng-l oaded fri cti on wheel whi ch el i mi nates
backl ash and thus reduces runni ng noi se. Thi s braces
the two wheel s agai nst one another and offsets the
teeth so that the backl ash i s el i mi nated between the
meshi ng gears.
Fig. 35 Oil Pump Removal
Fig. 36 Vacuum Pump
Fig. 37 Vacuum Pump Parts
9 - 28 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) To i nstal l the vacuum pump, al i gn the outer
part of the gear wi th the i nner part usi ng a screw-
dri ver or si mi l ar tool , al i gn wi th ti mi ng marks on
gear set and i nstal l .
(2) I nstal l bol ts and ti ghten to 20 Nm (15 ft. l bs.).
(3) I nstal l front cover.
OIL PUMP PRESSURE RELIEF VALVE
REMOVAL
(1) Remove oi l pan.
(2) Remove cl i p retai ni ng rel i ef val ve.
(3) Remove rel i ef val ve cap, spri ng, and pl unger
(Fi g. 40).
(4) Check rel i ef val ve spri ng l ength. Rel i ef val ve
spri ng free l ength i s 57.5mm (2.263 i n.). I f spri ng
l ength i s l ess or spri ng i s di storted i t must be
repl aced.
(5) Check pl unger for scori ng, repl ace i f necessary.
INSTALLATION
(1) Thoroughl y cl ean al l components and rel i ef
val ve pocket i n cyl i nder bl ock.
(2) Fi t pl unger, spri ng and cap i nto bl ock.
(3) Compress spri ng and i nstal l retai ni ng cl i p.
Ensure cl i p i s compl etel y seated i n groove.
OIL FILTER ADAPTER
REMOVAL
(1) Remove oi l fi l ter.
(2) Remove oi l fi l ter adapter wi th socket wrench.
(3) Remove oi l fi l ter base, al l en bol t i n center of
adapter.
Fig. 38 Vacuum Pump Mounting Hole
Fig. 39 Timing Marks
Fig. 40 Oil Pressure Relief Valve
ZG ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)
(4) Remove oi l cool er adapter bol t.
(5) Remove oi l cool er (Fi g. 41).
INSTALLATION
(1) I nstal l oi l cool er wi th new gasket, ti ghten oi l
cool er adapter bol t to 60 Nm (44 ft. l bs.).
(2) I nstal l oi l fi l ter base wi th new o-ri ng and
ti ghten bol t to 46.6 Nm (34 ft. l bs.).
(3) I nstal l oi l fi l ter adapter to oi l fi l ter base and
ti ghten to 46.6 Nm (34 ft. l bs.).
(4) I nstal l oi l fi l ter and ti ghten to 18 Nm (13 ft.
l bs.) and add oi l .
PISTONS AND CONNECTING ROD ASSEMBLY
REMOVAL
(1) Di sconnect the battery cabl e.
(2) Remove cyl i nder heads, refer to cyl i nder head
removal i n thi s secti on.
(3) Rai se vehi cl e on host.
(4) Remove oi l pan, refer to oi l pan removal i n thi s
secti on.
(5) Remove top ri dge of cyl i nder bores wi th a rel i -
abl e ri dge reamer before removi ng pi stons from cyl -
i nder bl ock. Be sure to keep tops of pistons
covered during this operation . Mark pi ston wi th
matchi ng cyl i nder number.
(6) Pi stons and connecti ng rods must be removed
from top of cyl i nder bl ock. Rotate crankshaft so that
each connecti ng rod i s centered i n cyl i nder bore.
(7) Remove connecti ng rod cap. I nstal l connecti ng
rod bol t protectors on connecti ng rod bol ts. Push each
pi ston and rod assembl y out of cyl i nder bore.
NOTE: Be careful not to nick crankshaft journals.
(8) After removal , i nstal l beari ng cap on the mat-
i ng rod.
PISTON PINREMOVAL
(1) Secure connecti ng rod i n a soft jawed vi ce.
(2) Remove 2 cl i ps securi ng pi ston pi n.
(3) Push pi ston pi n out of pi ston and connecti ng
rod.
PISTON RINGREMOVAL
(1) I D mark on face of upper and i ntermedi ate pi s-
ton ri ngs must poi nt toward pi ston crown.
(2) Usi ng a sui tabl e ri ng expander, remove upper
and i ntermedi ate pi ston ri ngs (Fi g. 43).
(3) Remove the upper oi l ri ng si de rai l , l ower oi l
ri ng si de rai l and then oi l ri ng expander from pi ston.
(4) Careful l y cl ean carbon from pi ston crowns,
ski rts and ri ng grooves ensuri ng the 4 oi l hol es i n
the oi l control ri ng groove are cl ear.
Fig. 41 Oil Cooler
Fig. 42 Piston Assembly
9 - 30 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
PISTON RING FITTING
(1) Wi pe cyl i nder bore cl ean. I nsert ri ng and push
down wi th pi ston to ensure i t i s square i n bore. The
ri ng gap measurement must be made wi th the ri ng
posi ti oni ng at l east 12 mm (0.50 i n.) from bottom of
cyl i nder bore. Check gap wi th feel er gauge. Top com-
pressi on ri ng gap .25 to .50mm (.0098 to .0196 i n.).
Second compressi on ri ng gap .25 to .35mm (.0098 to
.0137 i n.). Oi l control ri ng gap .25 to .58mm (.0098 to
.0228 i n.).
(2) I f ri ng gaps exceed di mensi on gi ven, new ri ngs
or cyl i nder l i ners must be fi tted. Keep pi ston ri ngs i n
pi ston sets.
(3) Check pi ston ri ng to groove cl earance. Top com-
pressi on ri ng gap .08 to .130mm (.0031 to .0051 i n.).
Second compressi on ri ng gap .070 to .102mm (.0027
to .0040 i n.). Oi l control ri ng gap .040 to .072mm
(.0015 to .0028 i n.).
PISTON RINGSINSTALLATION
(1) I nstal l ri ngs on the pi stons usi ng a sui tabl e
ri ng expander (Fi g. 46).
Fig. 43 Piston RingsRemoving and Installing
Fig. 44 Ring Gap Measurement
Fig. 45 Piston Ring Side Clearance
Fig. 46 Piston RingsRemoving and Installing
Fig. 47 Piston Ring Identification
ZG ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)
(2) Top compressi on ri ng i s tapered and chromi um
pl ated. The second ri ng i s of the scraper type and
must be i nstal l ed wi th scrapi ng edge faci ng bottom of
the pi ston. The thi rd i s an oi l control ri ng. Ri ng gaps
must be posi ti oned, before i nserti ng pi ston i nto the
l i ners, as fol l ows (Fi g. 48).
(3) Top ri ng gap must be posi ti oned at 30 degrees
to the ri ght of the combusti on chamber recess (l ook-
i ng at the pi ston crown from above).
(4) Second pi ston ri ng gap shoul d be posi ti oned on
the opposi te si de of the combusti on chamber recess.
(5) Oi l control ri ng gap to be l ocated 30 degrees to
the l eft of combusti on chamber recess.
(6) When assembl i ng pi stons check that compo-
nents are i nstal l ed i n the same posi ti on as before di s-
assembl y, determi ned by the numbers stamped on
the crown of i ndi vi dual pi stons. Engi ne cyl i nders are
numbered starti ng from gear trai n end of the engi ne.
Face chamber recess side of piston towards
camshaft . Therefore, the numbers stamped on con
rod bi g end shoul d al so face i n the same di recti on. To
i nsert pi ston i nto cyl i nder use a ri ng compressor as
shown i n (Fi g. 46).
PISTON PIN INSTALLATION
(1) Secure connecti ng rod i n soft jawed vi ce.
(2) Lubri cate pi ston pi n and pi ston wi th cl ean oi l .
(3) Posi ti on pi ston on connecti ng rod.
CAUTION: Ensure combustion recess in piston
crown and the bearing cap numbers on the con-
necting rod are on the same side.
(4) I nstal l pi ston pi n.
(5) I nstal l cl i ps i n pi ston to retai n pi ston pi n.
(6) Remove connecti ng rod from vi ce.
INSTALLATION
(1) Before i nstal l i ng pi stons, and connecti ng rod
assembl i es i nto the bore, be sure that compressi on
ri ng gaps are staggered so that nei ther i s i n l i ne wi th
oi l ri ng rai l gap (Fi g. 48).
(2) Before i nstal l i ng the ri ng compressor, make
sure the oi l ri ng expander ends are butted and the
rai l gaps l ocated as shown i n (Fi g. 48).
(3) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l , sl i de the ri ng compressor, over the pi ston
and ti ghten wi th the speci al wrench (Fi g. 49).
Ensure position of rings does not change dur-
ing this operation.
Fig. 48 Piston Ring Gap Location
Fig. 49 Installing Piston
9 - 32 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(4) Face chamber recess si de of pi ston towards
camshaft.
(5) I nstal l connecti ng rod bol t protectors on rod
bol ts.
(6) Rotate crankshaft so that the connecti ng rod
journal i s on the center of the cyl i nder bore. I nsert
rod and pi ston i nto cyl i nder bore and gui de rod over
the crankshaft journal .
(7) Tap the pi ston down i n cyl i nder bore, usi ng a
hammer handl e. At the same ti me, gui de connecti ng
rod i nto posi ti on on connecti ng rod journal .
(8) I nstal l rod caps. I nstal l nuts on cl eaned and
oi l ed rod bol ts and ti ghten nuts to 29.5 Nm (22 ft.
l b.) pl us 60.
CYLINDER WALL LINER ASSEMBLY
REMOVAL
(1) Remove cyl i nder heads.
(2) Remove Oi l pan.
(3) Remove pi stons.
(4) Use tool VM-1001 to remove l i ners (Fi g. 50).
(5) Remove shi ms from cyl i nder l i ner or cyl i nder
bl ock recess. Keep shi ms wi th each cyl i nder l i ner.
INSTALLATION
(1) Careful l y cl ean resi dual LOCTI TE from l i ner
and crankcase, and degrease the crankcase where i t
comes i nto contact wi th the l i ners. I nstal l the l i ners
i n the crankcase as shown (A), rotati ng them back
and forth by 45 i n order to guarantee correct posi -
ti oni ng (Fi g. 52).
Fig. 50 Liner Removal Tool
Fig. 51 Liner Inspection
ZG ENGINE 9 - 33
REMOVAL AND INSTALLATION (Continued)
(2) Measure the l i ner recess rel ati ve to bl ock deck
wi th a di al i ndi cator mounted on a speci al tool
VM-1010 A. All the measurements must be taken
on camshaft side . Zero di al gauge on bl ock deck.
(3) Move di al gauge to cyl i nder l i ner record read-
i ng on di al gauge.
(4) Remove l i ner and speci al tool .
(5) Then sel ect the correct shi m thi ckness to gi ve
proper protrusi on (0.01 - 0.06 mm).
(6) Fi t the shi m and the O-ri ngs onto the l i ner.
(7) Lubri cate the l ower l i ner l ocati on i n the bl ock.
Appl y LOCTI TE AVX to the corner of the l i ner seat.
Appl y LOCTI TE AVX uni forml y to the upper part of
the l i ner at area.
(8) Fi t the l i ners i n the crankcase maki ng sure
that the shi m i s posi ti oned correctl y i n the seat. Lock
the l i ners i n posi ti on usi ng speci al tool (VM-1016)
and bol ts (Fi g. 53). Cl ean the resi dual LOCTI TE on
the upper surface of the bl ock deck.
(9) Recheck the l i ner protrusi on. I t shoul d be 0.01
- 0.06 mm.
NOTE: A period of six hours must elapse between
the liners being installed and engine start-up. If
engine assembly is not continued after liner instal-
lation, the liners need to be clamped for twelve
hours minimum.
Fig. 52 Liner Installation
9 - 34 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Di sconnect battery cabl e.
(2) Remove engi ne from vehi cl e, refer to engi ne
removal i n thi s secti on.
(3) I nstal l engi ne to engi ne stand.
(4) Remove accessary dri ve system.
(5) Remove cyl i nder head cover, refer to cyl i nder
head cover removal i n thi s secti on.
(6) Remove rocker arm and push rods, refer to
rocker arm and push rod secti on i n thi s secti on.
(7) Remove i ntake, exhaust mani fol d and turbo-
charger, refer to Group 11, Exhaust System and
I ntake Mani fol d.
(8) Remove water mani fol d.
(9) Remove oi l feed l i nes to rocker arms.
(10) Remove cyl i nder heads.
(11) Remove oi l pan and oi l pi ck-up.
(12) Remove pi ston and connecti ng rods from
crankshaft journal s.
(13) Remove pi stons and connecti ng rods from
bl ock.
(14) Remove vi brati on damper, refer to vi brati on
damper removal i n thi s secti on.
(15) Remove front cover, refer to front cover
removal i n thi s secti on.
(16) Remove oi l pump and vacuum pump from
bl ock.
Fig. 54 Crankshaft and Bearing Assembly
Fig. 53 Liner Clamp Location
ZG ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)
(17) I nstal l speci al tool VM-1004 onto crankshaft
over gear (Fi g. 55).
(18) Remove mai n beari ng oi l feed and carri er
l ocators from bl ock.
(19) Remove fl ywheel and adaptor pl ate from
engi ne bl ock.
(20) Remove thrust beari ngs from rear mai n bear-
i ng carri er.
(21) Sl i de crankshaft and beari ng carri ers rear-
ward to rear of bl ock. I f you encounter di ffi cul ty i n
removi ng the compl ete assembl y as previ ousl y
descri bed, sl i de the assembl y rearward suffi ci entl y to
gai n access to the mai n beari ng carri er bol ts. Mark
the carri ers for assembl y and remove the bol ts, two
for each carri er (Fi g. 56).
(22) Separate the two hal ves of each carri er,
remove from the crankshaft and temporari l y re-as-
sembl e the carri ers (Fi g. 57). Wi thdraw the crank-
shaft through the rear of the crankcase.
INSTALLATION
(1) Fi t mai n beari ng carri ers together and torque
to 42 Nm (31 ft. l bs.)
(2) Check i nternal di ameter of beari ngs.
(3) I f i nternal di ameter of ori gi nal beari ng i s bei ng
checked and fi gures are not wi thi n speci fi cati ons,
new beari ngs must be used.
(4) Check crankshaft mai n beari ng journal s to
beari ng cl earances. Cl earances of mai n beari ngs i s
.03 to .088mm (.0011 to .0035 i n.).
NOTE: Assemble engine according to sequence
described, thus saving time and preventing dam-
ages to engine components. Clean parts with a suit-
able solvent and dry them with compressed air
before assembly. Use new gaskets where applicable
and torque wrenches for correct tightening of com-
ponents.
(5) Thoroughl y cl ean crankcase and oi l passages,
and bl ow dry wi th compressed ai r.
(6) I nstal l new mai n beari ng shel l s i n each of the
carri er hal ves. Assembl e the carri ers to the crank-
shaft journal s, ensuri ng that the carri ers are
i nstal l ed i n thei r ori gi nal l ocati ons and that the pis-
ton jet notch is towards the front of the crank-
shaft . Secure each carri er wi th the two bol ts
ti ghteni ng evenl y to 42 Nm (31 ft. l bs.). Check that
the oi l jet i s i n posi ti on (Fi g. 57).
Fig. 55 Crankshaft Special Tool VM-1004
Fig. 56 Carrier Bolts
Fig. 57 Crankshaft and Carrier Bearing Assembly
9 - 36 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(7) Sl i de speci al tool (VM-1002) over the crank-
shaft gear and, i nsert the crankshaft and carri er
assembl y i nto the crankcase i n the same manner
used for removal .
(8) Al i gn the hol es i n the l ower carri ers, wi th the
center of the crankcase webs (Fi g. 58).
(9) Secure each carri er assembl y to the crankcase
wi th the mai n beari ng oi l feed and carri er l ocators
and ti ghten them to 54 Nm (40 ft. l bs).
(10) I nstal l rear mai n beari ng carri er onto crank-
shaft ensuri ng arrow on beari ng carri er al i gns wi th
verti cal web i n center of crankcase.
(11) I nstal l rear oi l seal .
(12) I nstal l new O-ri ngs i n adaptor pl ate.
(13) I nstal l adaptor pl ate and ti ghten bol ts to 47
Nm (35 ft. l bs.).
(14) I nstal l bol ts to mai n beari ng carri er and
ti ghten to 26.5 Nm (20 ft. l bs.).
(15) Posi ti on fl ywheel and O-ri ng on crankshaft
and al i gn bol t hol es.
NOTE: For purposes of checking crankshaft end
play, used flywheel bolts may be used. Final assem-
bly requires new flywheel bolts.
(16) I nstal l 2 fl ywheel bol ts, 180 apart, and
ti ghten bol ts to 20 Nm pl us 60 (15 ft. l bs.) pl us 60.
(17) Attach di al i ndi cator to engi ne bl ock.
(18) Move crankshaft toward front of engi ne and
zero i ndi cator.
(19) Move crankshaft toward the rear of engi ne
and record measurement.
(20) Subtract speci fi ed crankshaft end pl ay from
fi gure obtai ned. Crankshaft end pl ay .153 to .304mm
(.0060 to .0119 i n.).
(21) Sel ect thrust washers whi ch wi l l gi ve correct
end pl ay.
(22) Remove tool s and fl ywheel .
(23) Lubri cate thrust washer hal ves and fi t them
i nto the rear mai n beari ng carri er.
(24) Ensure that crankshaft end and fl ywheel mat-
i ng surfaces are cl ean and dry. I nstal l O ri ng i n fl y-
wheel groove.
(25) To veri fy correct end pl ay, i nstal l 2 fl ywheel
bol ts 180 apart, and ti ghten bol ts to 20 Nm pl us 60
(15 ft. l bs. pl us 60).
(26) Measure crankshaft end pl ay wi th a di al
gauge. Crankshaft end pl ay shoul d not exceed .153 to
.304mm (.0060 to .0119 i n.) (Fi g. 59).
(27) Mount fl ywheel on crankshaft. Li ghtl y oi l and
i nstal l NEW bol ts, ti ghteni ng to 20 Nm i n di ametri -
cal l y opposi te pai rs. Check that al l bol ts are at 20
Nm. Ti ghten each bol t a further 60 +0-5, ti ghten-
i ng bol ts i n di ametral pai rs. Check that al l bol ts are
ti ghtened to 130 Nm.
(28) I nstal l pi stons and connecti ng rod assembl i es,
refer to pi ston and connecti ng rods i n thi s secti on.
(29) I nstal l oi l pi ck up tube and ti ghten bol ts to 25
Nm (18 ft. l bs.).
(30) I nstal l oi l pan, refer to oi l pan i nstal l ati on i n
thi s secti on.
(31) I nstal l vacuum pump, bei ng careful to al i gn
the gear ti mi ng marks wi th those on the crankshaft
gear. Ti ghten retai ni ng screws to 20 Nm (15 ft. l bs.).
Fig. 58 Main Bearing Carrier Alignment
Fig. 59 Measuring Crankshaft End Play
ZG ENGINE 9 - 37
REMOVAL AND INSTALLATION (Continued)
(32) Before i nstal l i ng oi l pump check pump bore
depth i n bl ock (A) and pump body hei ght (B) (Fi g.
60). Di fference between A and B shoul d be
0.020-0.082 mm (.0007 to 0032 i n.).
(33) I nstal l oi l pump and ti ghten retai ni ng screws
to 27 NM (20 ft.l bs.). Check for normal backl ash
between pump and crankshaft gears.
(34) I nstal l front cover, refer to front cover i nstal -
l ati on i n thi s secti on.
(35) I nstal l vi brati on damper, refer to vi brati on
damper i nstal l ati on i n thi s secti on.
(36) I nstal l cyl i nder heads, refer to cyl i nder head
i nstal l ati on i n thi s secti on.
(37) I nstal l rocker arms and push rods, refer to
rocker arm and push rod i n thi s secti on.
(38) I nstal l cyl i nder head cover, refer to cyl i nder
head cover i n thi s secti on.
(39) I nstal l accessary dri ve system.
(40) I nstal l engi ne i n vehi cl e, refer to engi ne
i nstal l ati on i n thi s secti on.
(41) Fi l l engi ne wi th the correct amount of fl ui ds
speci fi ed.
(42) Connect battery cabl e.
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS
DISASSEMBLE
(1) Pry out pl unger retai ner spri ng cl i p.
(2) Cl ean varni sh deposi ts from i nsi de of tappet
body above pl unger cap.
(3) I nvert tappet body and remove pl unger cap,
pl unger, check val ve, check val ve spri ng, check val ve
retai ner and pl unger spri ng. Check val ve coul d be
fl at or bal l .
ASSEMBLE
(1) Cl ean al l tappet parts i n a sol vent that wi l l
remove al l varni sh and carbon.
(2) Repl ace tappets that are unfi t for further ser-
vi ce wi th new assembl i es.
(3) I f pl unger shows si gns of scori ng or wear,
i nstal l a new tappet assembl y. I f val ve i s pi tted, or
val ve seat on end of pl unger i s prevented from seat-
i ng, i nstal l a new tappet assembl y.
(4) Assembl e tappets.
CLEANING AND INSPECTION
CYLINDER HEAD
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
exhaust mani fol d and engi ne cyl i nder head mati ng
surfaces. Remove al l gasket materi al and carbon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces (Fi g. 61).
Mi ni mum cyl i nder head thi ckness 89.95mm (3.541
i n.)
CAUTION: If only one cylinder head is found to be
distorted and requires machining, it will also be
necessary to machine the remaining cylinders
heads and end plates by a corresponding amount
to maintain correct cylinder alignment.
Fig. 60 Oil Pump Bore Depth
Fig. 61 Checking Cylinder Head Flatness
9 - 38 ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
ROCKER ARMS AND PUSH RODS
CLEANING
Cl ean al l the components (Fi g. 62) wi th cl eani ng
sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
PISTONS AND CONNECTING ROD ASSEMBLY
INSPECTIONPISTONS
(1) Pi ston Di ameter: Si ze Group A: 91.93-91.94mm
(3.6191-3.6196 i n.) Si ze Group B: 91.94-91.95mm
(3.6196-3.6200 i n.). Maxi mum wear l i mi t .05mm
(.0019 i n.).
(2) Check pi ston pi n bores i n pi ston for roundness.
Make 3 checks at 120 i nterval s. Maxi mum out of
roundness .05mm (.0019i n.).
(3) The pi ston di ameter shoul d be measured
approxi matel y 15 mm (.590 i n.) up from the base.
(4) Ski rt wear shoul d not exceed 0.1 mm (.00039
i n.).
(5) The cl earance between the cyl i nder l i ner and
pi ston shoul d not exceed 0.25 mm (.0009 i n.).
(6) Make sure the wei ght of the pi stons does not
di ffer by more than 5 g.
INSPECTIONCONNECTING ROD
(1) Assembl e beari ng shel l s and beari ng caps to
thei r respecti ve connecti ng rods ensuri ng that the
serrati ons on the cap and reference marks are
al i gned.
(2) Ti ghten beari ng cap bol ts to 29Nm (21 ft. l bs.)
pl us 60.
(3) Check and record i nternal di ameter of crank
end of connecti ng rod.
NOTE: When changing connecting rods, all four
must have the same weight and be stamped with
the same number. Replacement connecting rods
will only be supplied in sets of four.
Connecti ng rods are suppl i ed i n sets of four si nce
they al l must be of the same wei ght category. Max
al l owabl e wei ght di fference i s 18 gr.
NOTE: On one side of the big end of the con-rod
there is a two-digit number which refers to the
weight category. On the other side of the big end
there is a four digit number on both the rod and the
cap. These numbers must both face the camshaft
as well as the recess on the piston crown (Fig. 64).
Lightly heat the piston in oven. Insert piston pin in
position and secure it with provided snap rings.
Fig. 62 Rocker Arm Components
ZG ENGINE 9 - 39
CLEANING AND INSPECTION (Continued)
The Four digit numbers marked on con rod
big end and rod cap must be on the same side
as the camshaft (Fig. 64). After havi ng coated
threads wi th Mol yguard, ti ghten con rod bol ts to 29
Nm (21 ft. l bs.) pl us 60.
INSPECTIONPISTON PIN
(1) Measure the di ameter of pi ston pi n i n the cen-
ter and both ends.
(2) Pi ston pi n di ameter i s 29.990 to 29.996mm
(1.1807 to 1.1809 i n.).
INSPECTIONCRANKSHAFT J OURNALS
(1) Usi ng a mi crometer, measure and record crank-
shaft connecti ng rod journal s, take readi ng of each
journal 120 apart. Crankshaft journal di ameter i s
53.84 to 53.955mm (2.1196 to 2.1242 i n.).
(2) Crankshaft journal s worn beyond l i mi ts or
show si gns of out of roundness must be reground or
repl aced. Mi ni mum reground di ameter i s 53.69mm
(2.1137 i n.).
BEARING-TO-J OURNAL CLEARANCE
Compare i nternal di ameters of connecti ng rod wi th
crankshaft journal di ameter. Maxi mum cl earance
between connecti ng rod and crankshaft journal s .022
to .076mm (.0008 to .0029 i n.).
CYLINDER WALL LINER ASSEMBLY
INSPECTION
The cyl i nder wal l s shoul d be checked for out-of-
round and taper wi th dai l bore gauge. The cyl i nder
bore out-of-round i s 0.100 mm (.0039 i nch) maxi mum
and cyl i nder bore taper i s 0.100 mm (0.0039 i nch)
maxi mum. I f the cyl i nder wal l s are badl y scuffed or
scored, new l i ners shoul d be i nstal l ed and honed, and
new pi stons and ri ngs fi tted.
Measure the cyl i nder bore at three l evel s i n di rec-
ti ons A and B (Fi g. 66). Top measurement shoul d be
10 mm ( 3/8 i nch) down and bottom measurement
shoul d be 10 mm ( 3/8 i nch.) up from bottom of bore.
Fig. 63 Connecting Rod Identification
Fig. 64 Piston and Connecting Rod Assembly
Fig. 65 Bearing Clearance
9 - 40 ENGINE ZG
CLEANING AND INSPECTION (Continued)
OIL PUMP
CLEANING
Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
INSPECTION
(1) Before i nstal l i ng oi l pump check pump bore
depth i n bl ock (A) and pump body hei ght (B) (Fi g.
67). Di fference between A and B shoul d be
0.020-0.082 mm.
(2) Check cl earance between rotors (Fi g. 69).
Fig. 66 Liner Inspection
Fig. 67 Oil Pump Bore Depth
Fig. 68 Oil Pump Inner and Outer Rotors
Fig. 69 Checking Rotor Clearance
ZG ENGINE 9 - 41
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
ENGINE SPECIFICATIONS
9 - 42 ENGINE ZG
ZG ENGINE 9 - 43
SPECIFICATIONS (Continued)
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Automatic Belt Tensioner to Block
Bol ts (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Nm
Automatic Belt Tensioner to Mounting Bracket
Bol t (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Nm
Generator belt
Tensi oner . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Nm
Generator bracket
Mounti ng bol ts (6 mm) . . . . . . . . . . . . . . . . . 10 Nm
Mounti ng bol ts (8 mm) . . . . . . . . . . . . . . . 24.4 Nm
Generator
Mounti ng bol t . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Camshaft thrust plate
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm
Connecting rod
Mounti ng bol t . . . . . . . . . . . . . . . . . . 29.5 Nm +60
Crankshaft bearing
Carri er screw . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm
Crankshaft pulley
Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm
Crossmember
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm
Diesel delivery
Uni on nut . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 Nm
EGR valve
To i ntake mani fol d . . . . . . . . . . . . . . . . . . . . 26 Nm
EGR tube
To EGR val ve . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Engine mountFront
Engi ne support bracket . . . . . . . . . . . . . . . . 61 Nm
Support Cushi on . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Support cushi on bracket bol ts . . . . . . . . . . . 54 Nm
Support cushi on bracket stud nuts . . . . . . . . 41 Nm
Support Cushi on through bol t . . . . . . . . . . . 65 Nm
Engine mountRear
Transmi ssi on support bracket . . . . . . . . . . . 46 Nm
Support Cushi on nuts . . . . . . . . . . . . . . . . . . 75 Nm
Support Cushi on through bol t . . . . . . . . . . . 65 Nm
Exhaust down pipe
To turbocharger . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Exhaust heat shield
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm
Exhaust manifold collar
Mounti ng nut . . . . . . . . . . . . . . . . . 24.5 to 29.5 Nm
Exhaust manifold
Mounti ng nut . . . . . . . . . . . . . . . . . . . . . . . 32.5 Nm
Fan drive
To fan hub . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Nm
Flywheel
Lock bol t . . . . . . . . . . . . . . . . . . . . . . . 20 Nm +60
Flywheel plate
Mounti ng bol t . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
DESCRIPTION TORQUE
Front timing cover
6 mm bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
8 mm bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm
Fuel filter
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
Glow plug
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0 Nm
Idler pulley bracket
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Idler pulley
Bol t (l eft hand thread) . . . . . . . . . . . . . . . . . 47 Nm
Injection pump fuel lines
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Injection pump gear
Lock nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Nm
Injection pump
Mounti ng nut . . . . . . . . . . . . . . . . . . . . . . . 27.5 Nm
Injector
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 Nm
Intake manifold
Mounti ng nut . . . . . . . . . . . . . . . . . . . . . . . 32.5 Nm
Main bearing oil delivery
Uni on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Nm
Water hose to cylinder head
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 10 Nm
Oil cooler adaptor
Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Oil feed line
For rocker arms . . . . . . . . . . . . . . . . . . . . . . 12 Nm
To bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
To vacuum pump . . . . . . . . . . . . . . . . . . . . . 15 Nm
Oil filter
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm
Oil filter adapter
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.6 Nm
Oil filter base
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.6 Nm
Oil pan
Mounti ng bol ts . . . . . . . . . . . . . . . . . . . . . . . 13 Nm
Oil pickup tube
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Oil pump
Mounti ng screw . . . . . . . . . . . . . . . . . . . . . . 27 Nm
Oil sump drain plug
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Nm
Power steering pressure hose
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
Power steering pulley
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Nm
Rear crankshaft bearing carrier
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 Nm
Rocker cover
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Nm
9 - 44 ENGINE ZG
SPECIFICATIONS (Continued)
DESCRIPTION TORQUE
Rocker mounting
Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Steering pump
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
Turbocharger
Mounti ng nuts . . . . . . . . . . . . . . . . . . . . . . 32.5 Nm
Turbocharger
Oi l del i very fi tti ng . . . . . . . . . . . . . . . . . . . 27.5 Nm
Turbocharger oil drain
Pl ug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 Nm
Vacuumpump
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
Water manifold
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Water pump pulley
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
SPECIAL TOOLS
SPECIAL TOOLS
Crankshaft Pulley and Gear Remover VM. 1000A
Cylinder Liner Puller VM, 1001
Crankshaft Bearing Remover/Replacer VM. 1002
Injection Pump Puller and Gear retainer VM. 1003
ZG ENGINE 9 - 45
SPECIFICATIONS (Continued)
Crankshaft Remover/Replacer Sleeve VM. 1004
Torque Angle Gauge VM. 1005
Cylinder Head Bolt Wrench VM. 1006A
Cylinder Head Guide Studs VM. 1009
Cylinder Liner Protrusion Tool VM. 1010
Bosch Pump Timing Adapter VM. 1011
9 - 46 ENGINE ZG
SPECIAL TOOLS (Continued)
Injector Remover/Replacer Socket VM. 1012
Dial Indicator Gauge VM. 1013
Flywheel Locking Tool VM. 1014
Timing Cover Oil Seal Replacer VM. 1015
Cylinder Retainer VM. 1016
Crankshaft and Water Pump Pulley Holder VM. 1017
ZG ENGINE 9 - 47
SPECIAL TOOLS (Continued)
Cylinder Head Bolt Wrench M12 VM. 1018
Cylinder Head Bolt Wrench M14 VM. 1019
Cylinder Leakage Tester Adapter VM. 1021
9 - 48 ENGINE ZG
SPECIAL TOOLS (Continued)
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . 2
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . 4
EXHAUST MANIFOLD5.2/5.9L ENGINE . . . . . . 8
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTAKE AND EXHAUST MANIFOLD4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTAKE MANIFOLD5.2/5.9L ENGINE . . . . . . . 6
MUFFLER AND TAILPIPE . . . . . . . . . . . . . . . . . . 5
CLEANING AND INSPECTION
EXHAUST MANIFOLD5.2/5.9L ENGINE . . . . . . 9
INTAKE AND EXHAUST MANIFOLD4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INTAKE MANIFOLD 5.2/5.9L ENGINE . . . . . . . 9
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
EXHAUST SYSTEM
The basi c exhaust system consi sts of exhaust man-
i fol d(s), exhaust pi pe wi th oxygen sensor, catal yti c
converter, heat shi el d(s), muffl er and tai l pi pe (Fi g. 1)
or (Fi g. 2).
The exhaust system uses a si ngl e muffl er wi th a
si ngl e monol i thi c- type catal yti c converter.
The 4.0L engi nes use a seal between the exhaust
mani fol d and exhaust pi pe to assure a ti ght seal and
strai n free connecti ons.
The 5.2/5.9L exhaust mani fol ds are equi pped wi th
bal l fl ange outl ets to assure a ti ght seal and strai n
free connecti ons.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. I f the sys-
tem contacts any body panel , i t may ampl i fy objec-
ti onabl e noi ses ori gi nati ng from the engi ne or body.
When i nspecti ng an exhaust system, cri ti cal l y
i nspect for cracked or l oose joi nts, stri pped screw or
bol t threads, corrosi on damage and worn, cracked or
broken hangers. Repl ace al l components that are
badl y corroded or damaged. DO NOT attempt to
repai r.
Fig. 1 Exhaust System4.0LEngine
Fig. 2 Exhaust System5.2/5.9L Engine
EXHAUST MANI- FOLD (RIGHT) EXHAUST MANI- FOLD (LEFT) CATALYTIC CON- VERTER EXHAUST PIPE MUFFLER TAILPIPE
ZG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
When repl acement i s requi red, use ori gi nal equi p-
ment parts (or thei r equi val ent). Thi s wi l l assure
proper al i gnment and provi de acceptabl e exhaust
noi se l evel s.
CAUTION: Avoid application of rust prevention
compounds or undercoating materials to exhaust
system floor pan heat shields. Light overspray near
the edges is permitted. Application of coating will
result in excessive floor pan temperatures and
objectionable fumes.
CATALYTIC CONVERTER
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unl eaded gasol i ne must be used to avoi d contami -
nati ng the catal yst core.
DO NOT remove spark pl ug wi res from pl ugs or by
any other means short out cyl i nders. Fai l ure of the
catal yti c converter can occur due to a temperature
i ncrease caused by unburned fuel passi ng through
the converter.
DO NOT al l ow the engi ne to operate at fast i dl e for
extended peri ods (over 5 mi nutes). Thi s condi ti on
may resul t i n excessi ve temperatures i n the exhaust
system and on the fl oor pan.
HEAT SHIELDS
Heat shi el ds are needed to protect both the vehi cl e
and the envi ronment from the hi gh temperatures
devel oped by the catal yti c converter (Fi g. 3) (Fi g. 4).
The catal yti c converter rel eases addi ti onal heat i nto
the exhaust system. Under severe operati ng condi -
ti ons, the temperature i ncreases i n the area of the
converter. Such condi ti ons can exi st when the engi ne
mi sfi res or otherwi se does not operate at peak effi -
ci ency.
Fig. 3 Front Floor Pan Heat Shield
FRONT FLOOR PAN FWD REAR FLOOR PAN FRONT FLOOR PAN HEAT SHIELD FRONT FLOOR PAN HEAT SHIELD ASSEMBLY
Fig. 4 Rear Floor Pan Heat Shield
FWD PUSH SCREW UNDERBODY ASSEMBLY REAR FLOOR PAN HEAT SHIELD
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD ZG
GENERAL INFORMATION (Continued)
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS
REMOVAL AND INSTALLATION
EXHAUST PIPE
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Rai se and support the vehi cl e.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the oxygen sensor from the exhaust
pi pe (Fi g. 5) (Fi g. 6).
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d. On 4.0L engi nes, di scard the
exhaust mani fol d seal (Fi g. 5).
(a) Heat the exhaust pi pe and catal yti c con-
verter connecti on wi th an torch unti l the metal
becomes cherry red.
(b) Whi l e the metal i s sti l l cherry red, twi st the
exhaust pi pe back and forth to separate i t from the
catal yti c converter.
(5) Remove the exhaust cl amp from the exhaust
pi pe and catal yti c converter connecti on (Fi g. 5) (Fi g.
6). Di sconnect the exhaust pi pe from the catal yti c
converter. I f needed:
(6) Di sconnect the exhaust pi pe hanger from the
rear mount bracket i nsul ator (Fi g. 7).
(7) Remove the exhaust pi pe.
INSTALLATION
(1) Posi ti on the exhaust pi pe onto the catal yti c
converter.
(2) Connect the exhaust pi pe hanger to the rear
mount bracket i nsul ator.
(3) On 4.0L engi nes, i nstal l a new seal between
the exhaust pi pe and the engi ne exhaust mani fol d
(Fi g. 5). Connect the exhaust pi pe to the engi ne
exhaust mani fol d. Ti ghten the nuts to 31 Nm (23 ft.
l bs.) torque.
(4) Posi ti on the exhaust cl amp over the exhaust
pi pe/catal yti c converter connecti on (Fi g. 5) (Fi g. 6).
Ti ghten the nuts to 61 Nm (45 ft. l bs.) torque.
(5) Coat the oxygen sensor wi th anti -sei ze com-
pound. I nstal l the sensor and ti ghten the nut to 48
Nm (35 ft. l bs.) torque.
(6) Lower the vehi cl e.
(7) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
(8) After i ni ti al start-up, check the engi ne exhaust
mani fol d to exhaust pi pe nuts for proper torque.
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or blown out muffler. 2. Replace muffler assembly. Check
exhaust system.
3. Burned or rusted-out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten connection attaching
nuts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head stud nuts or bolts.
7. Restriction in muffler or tailpipe. 7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
8. Exhaust system contacting body
or chassis.
8. Re-align exhaust system to clear
surrounding components.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten/replace clamps at leaking
joints.
2. Damaged or improperly installed
gaskets.
2. Replace gaskets as necessary
ZG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
CATALYTIC CONVERTER
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Rai se and support the vehi cl e.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove exhaust cl amp from the catal yti c con-
verter and exhaust pi pe connecti on (Fi g. 8).
(4) Remove exhaust cl amp from the catal yti c con-
verter and muffl er connecti on (Fi g. 8).
(5) Di sconnect oxygen sensor wi ri ng.
(6) Heat the exhaust pi pe, catal yti c converter and
muffl er connecti ons wi th an torch unti l the metal
becomes cherry red.
Fig. 5 Exhaust System4.0L Engine
Fig. 6 Exhaust Pipe4.7LEngines
Fig. 7 Rear Mount Bracket Insulator
REAR MOUNT BRACKET INSULATOR EXHAUST PIPE HANGER
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD ZG
REMOVAL AND INSTALLATION (Continued)
(7) Whi l e the metal i s sti l l cherry red, twi st the
catal yti c converter back and forth to separate i t from
the exhaust pi pe and the muffl er.
INSTALLATION
(1) Posi ti on the exhaust cl amp over the exhaust
pi pe/catal yti c converter connecti on (Fi g. 8). Ti ghten
the nuts to 61 Nm (45 ft. l bs.) torque.
(2) I nstal l the muffl er onto the catal yti c converter
unti l the al i gnment tab i s i nserted i nto the al i gn-
ment sl ot.
(3) I nstal l the exhaust cl amp at the muffl er and
catal yti c converter connecti on (Fi g. 8). Ti ghten the
cl amp nuts to 61 Nm (45 ft. l bs.) torque.
(4) Connect oxygen sensor wi ri ng.
(5) Lower the vehi cl e.
(6) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
MUFFLER AND TAILPIPE
REMOVAL
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the tai l pi pe wel ded to the muffl er. Ser-
vi ce repl acement muffl ers and tai l pi pes are ei ther
cl amped together or wel ded together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Rai se and support the vehi cl e.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the exhaust cl amp from the catal yti c
converter and muffl er connecti on (Fi g. 8).
(4) Heat the catal yti c converter-to-muffl er connec-
ti on wi th an torch unti l the metal becomes cherry
red.
(5) Whi l e the metal i s sti l l cherry red, remove the
tai l pi pe/muffl er assembl y from the catal yti c con-
verter.
(6) Remove the tai l pi pe from the tai l pi pe hanger
(Fi g. 9).
(7) Remove the tai l pi pe/muffl er assembl y.
INSTALLATION
(1) I f the tai l pi pe hanger assembl y was removed,
i nstal l the hanger to the frame. Ti ghten the bol ts to
22 Nm (192 i n. l bs.) torque.
(2) Posi ti on the tai l pi pe and muffl er onto the
tai l pi pe hanger (Fi g. 9).
(3) I nstal l the muffl er onto the catal yti c converter.
Make sure that the tai l pi pe has suffi ci ent cl earance
from the fl oor pan. I nstal l exhaust cl amp and ti ghten
the nuts to 61 Nm (45 ft. l bs.) torque.
(4) Lower the vehi cl e.
(5) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
INTAKE AND EXHAUST MANIFOLD4. 0L ENGINE
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Di sconnect the negati ve cabl e from the battery.
(2) Remove ai r cl eaner i nl et hose from throttl e
pl ate assembl y.
Fig. 8 Exhaust Pipe-to-CatalyticConverter-to-Muffler
Connection
Fig. 9 Tailpipe Hanger
TAILPIPE HANGER ASSEMBLY FWD TAILPIPE
ZG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5
REMOVAL AND INSTALLATION (Continued)
(3) Remove the ai r cl eaner assembl y.
(4) Remove the throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped) and the transmi ssi on l i ne pres-
sure cabl e.
(5) Di sconnect al l el ectri cal connectors on the
i ntake mani fol d.
(6) Di sconnect and remove the fuel system suppl y
and return l i nes from the fuel rai l assembl y (refer to
Group 14, Fuel System).
(7) Loosen the accessory dri ve bel t (refer to Group
7, Cool i ng System). Loosen the tensi oner.
(8) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and set asi de.
(9) Remove the fuel rai l and i njectors (refer to
Group 14, Fuel System).
(10) Rai se the vehi cl e.
(11) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d. Di scard the seal .
(12) Lower the vehi cl e.
(13) Remove the i ntake mani fol d and engi ne
exhaust mani fol d.
INSTALLATION
I f the mani fol d i s bei ng repl aced, ensure al l the fi t-
ti ng, etc. are transferred to the repl acement mani -
fol d.
(1) I nstal l a new engi ne exhaust/i ntake mani fol d
gasket over the al i gnment dowel s on the cyl i nder
head.
(2) Posi ti on the engi ne exhaust mani fol d to the
cyl i nder head. I nstal l fastener Number 3 and fi nger
ti ghten at thi s ti me (Fi g. 10).
(3) I nstal l i ntake mani fol d on the cyl i nder head
dowel s.
(4) I nstal l washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fi g. 10).
(5) I nstal l washer and fastener Numbers 6 and 7
(Fi g. 10).
(6) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 10).
Fastener Numbers 1 through 5Ti ghten to 33
Nm (24 ft. l bs.) torque.
Fastener Numbers 6 and 7Ti ghten to 31 Nm
(23 ft. l bs.) torque.
Fastener Numbers 8 through 11Ti ghten to 33
Nm (24 ft. l bs.) torque.
(7) I nstal l the fuel rai l and i njectors (refer to
Group 14, Fuel System).
(8) I nstal l the power steeri ng pump and bracket to
the i ntake mani fol d. Ti ghten the bel t to speci fi cati on
(refer to Group 7, Cool i ng System for the proper pro-
cedures).
(9) I nstal l the fuel system suppl y and return l i nes
to the fuel rai l assembl y. Before connecting the
fuel system lines to the fuel rail replace the
O-rings in the quick-connect fuel line cou-
plings. Refer to Group 14, Fuel System for the
proper procedure.
(10) Connect al l el ectri cal connecti ons on the
i ntake mani fol d.
(11) Connect the vacuum connector on the i ntake
mani fol d and i nstal l i t i n the bracket.
(12) I nstal l throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped).
(13) I nstal l the transmi ssi on l i ne pressure cabl e (i f
equi pped). Refer to Group 21, Transmi ssi on for the
adjustment procedures.
(14) I nstal l ai r cl eaner assembl y.
(15) Connect ai r i nl et hose to the throttl e pl ate
assembl y.
(16) Rai se the vehi cl e on a si de mounted hoi st.
(17) Use a new engi ne exhaust mani fol d seal . Con-
nect the exhaust pi pe to the engi ne exhaust mani -
fol d.
(18) Lower the vehi cl e.
(19) Connect the negati ve cabl e to the battery.
(20) Start the engi ne and check for l eaks.
INTAKE MANIFOLD5. 2/5. 9L ENGINE
REMOVAL
The al umi num i ntake mani fol d i s a si ngl e pl ane
desi gn wi th equal l ength runners. The mani fol d i s
seal ed by fl ange si de gaskets wi th front and rear
cross-over gaskets. The i ntake mani fol d has i nternal
EGR.
(1) Di sconnect the negati ve cabl e from the battery.
(2) Drai n the cool i ng system (refer to Group 7,
Cool i ng System for the proper procedures).
(3) Remove the generator (refer to Group 8B Bat-
tery/Starti ng/Chargi ng Systems).
(4) Remove the ai r cl eaner.
(5) Remove the fuel l i nes and fuel rai l (refer to
Group 14, Fuel System).
Fig. 10 Engine Exhaust/Intake Manifold
CYLINDER HEAD DOWEL INTAKE MANI- FOLD CYLINDER HEAD DOWEL EXHAUST MANIFOLD BOLT TORQUE 33 Nm (24 ft. lbs.)
23 Nm (17 ft. lbs.)
33 Nm (24 ft. lbs.)
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD ZG
REMOVAL AND INSTALLATION (Continued)
(6) Di sconnect the accel erator l i nkage and, i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(7) Remove the return spri ng.
(8) Remove the di stri butor cap and wi res.
(9) Di sconnect the coi l wi res.
(10) Di sconnect the heat i ndi cator sendi ng uni t
wi re.
(11) Di sconnect the heater hoses and bypass hose.
(12) Remove the cl osed crankcase venti l ati on and
evaporati on control systems.
(13) Remove the A/C compressor bol ts and set the
compressor on the fan shroud.
(14) Remove the support bracket from the i ntake
mani fol d and the mounti ng bracket.
(15) Remove i ntake mani fol d bol ts.
(16) Li ft the i ntake mani fol d and throttl e body out
of the engi ne compartment as an assembl y.
(17) Remove and di scard the fl ange si de gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttl e body bol ts and l i ft the
throttl e body off the i ntake mani fol d. Di scard the
throttl e body gasket.
(19) Remove the pl enum pan as fol l ows:
(a) Turn the i ntake mani fol d upsi de down. Sup-
port the mani fol d.
(b) Remove the bol ts and l i ft the pan off the
mani fol d. Di scard the gasket.
INSTALLATION
(1) I nstal l the pl enum pan, i f removed, as fol l ows:
(a) Turn the i ntake mani fol d upsi de down. Sup-
port the mani fol d.
(b) Pl ace a new pl enum pan gasket onto the seal
rai l of the i ntake mani fol d. Posi ti on the pan over
the gasket. Al i gn al l the gasket and pan hol es wi th
the i ntake mani fol d.
(c) Hand start al l bol ts.
(d) Ti ghten the bol ts, i n sequence (Fi g. 11), as
fol l ows:
Step 1Ti ghten bol ts to 2.7 Nm (24 i n. l bs.)
torque.
Step 2Ti ghten bol ts to 5.4 Nm (48 i n. l bs.)
torque.
Step 3Ti ghten bol ts to 9.5 Nm (84 i n. l bs.)
torque.
Step 4Check that al l bol ts are ti ghten to 9.5
Nm (84 i n. l bs.) torque.
(2) Usi ng a new gasket, i nstal l the throttl e body
onto the i ntake mani fol d. Ti ghten the bol ts to 23 Nm
(200 i n. l bs.) torque.
(3) Pl ace the 4 pl asti c l ocator dowel s i nto the hol es
i n the bl ock (Fi g. 12).
(4) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent, to the four corner joi nts. An exces-
si ve amount of seal ant i s not requi red to ensure a
l eak proof seal . However, an excessi ve amount of
seal ant may reduce the effecti veness of the fl ange
gasket. The seal ant shoul d be sl i ghtl y hi gher than
the cross-over gaskets, approxi matel y 5 mm (0.2 i n).
(5) I nstal l the front and rear cross-over gaskets
onto the dowel s (Fi g. 12).
(6) I nstal l the fl ange gaskets. Ensure that the ver-
ti cal port al i gnment tab i s resti ng on the deck face of
the bl ock. Al so the hori zontal al i gnment tabs must be
i n posi ti on wi th the mati ng cyl i nder head gasket tabs
Fig. 11 Plenum Pan Bolt TighteningSequence
Fig. 12 Cross-Over Gaskets and Locator Dowels
FRONT CROSS-OVER GASKET LOCATOR DOWELS REAR CROSS-OVER GASKET
ZG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7
REMOVAL AND INSTALLATION (Continued)
(Fi g. 13). The words MANI FOLD SI DE shoul d be vi s-
i bl e on the center of each fl ange gasket.
(7) Careful l y l ower i ntake mani fol d i nto posi ti on
on the cyl i nder bl ock and cyl i nder heads. Use the
al i gnment dowel s i n the cross-over gaskets to posi -
ti on the i ntake mani fol d. After i ntake mani fol d i s i n
pl ace, i nspect to make sure seal s are i n pl ace.
(8) The fol l owi ng torque sequence dupl i cates the
expected resul ts of the automated assembl y system
(Fi g. 14).
Step 1Ti ghten bol ts 1 through 4, i n sequence,
to 8 Nm (72 i n. l bs.) torque. Ti ghten i n al ternati ng
steps 1.4 Nm (12 i n. l bs.) torque at a ti me.
Step 2Ti ghten bol ts 5 through 12, i n sequence,
to 8 Nm (72 i n. l bs.) torque.
Step 3Check that al l bol ts are ti ghten to 8
Nm (72 i n. l bs.) torque.
Step 4Ti ghten al l bol ts, i n sequence, to 16 Nm
(12 ft. l bs.) torque.
Step 5Check that al l bol ts are ti ghten to 16
Nm (12 ft. l bs.) torque.
(9) I nstal l cl osed crankcase venti l ati on and evapo-
rati on control systems.
(10) I nstal l the coi l wi res.
(11) Connect the heat i ndi cator sendi ng uni t wi re.
(12) Connect the heater hoses and bypass hose.
(13) I nstal l di stri butor cap and wi res.
(14) Hook up the return spri ng.
(15) Connect the accel erator l i nkage and, i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(16) I nstal l the fuel l i nes and fuel rai l (refer to
Group 14, Fuel System).
(17) I nstal l the support bracket to the i ntake man-
i fol d and the mounti ng bracket.
(18) I nstal l the generator and dri ve bel t. Ti ghten
generator mounti ng bol t to 41 Nm (30 ft. l bs.)
torque. Ti ghten the adjusti ng strap bol t to 23 Nm
(200 i n. l bs.) torque. Refer to Group 7, Cool i ng Sys-
tem for the proper adjusti ng of bel t tensi on.
(19) I nstal l the A/C compressor on the mounti ng
bracket (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng).
(20) I nstal l the ai r cl eaner.
(21) Fi l l cool i ng system (refer to Group 7, Cool i ng
System for the proper procedure).
(22) Connect the negati ve cabl e to the battery.
EXHAUST MANIFOLD5. 2/5. 9L ENGINE
REMOVAL
Exhaust mani fol ds are LOG type wi th bal anced
fl ow.
(1) Di sconnect the negati ve cabl e from the battery.
(2) Remove the exhaust mani fol d heat shi el ds (Fi g.
15).
(3) Remove the EGR tube (refer to Group 25,
Emi ssi on Control Systems).
(4) Rai se the vehi cl e.
(5) Remove the bol ts and nuts attachi ng the
exhaust pi pe to the exhaust mani fol d.
(6) Lower the vehi cl e.
(7) Remove bol ts, nuts and washers attachi ng
mani fol d to cyl i nder head.
(8) Remove mani fol d from the cyl i nder head.
Fig. 13 Intake Manifold Flange Gasket Alignment
FLANGE GASKET ALIGNMENT TABS CYLINDER HEAD GASKET
Fig. 14 Intake Manifold Bolt Tightening Sequence
FRONT OF ENGINE
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
CAUTION: If the studs came out with the nuts
when removing the exhaust manifold, install new
studs.
(1) Posi ti on the exhaust mani fol ds on the two
studs l ocated on the cyl i nder head. I nstal l coni cal
washers and nuts on these studs (Fi g. 16).
(2) I nstal l new bol t and washer assembl i es i n the
remai ni ng hol es (Fi g. 16). Start at the center arm
and work outward. Ti ghten the bol ts and nuts to 27
Nm (20 ft. l bs.) torque.
(3) Rai se the vehi cl e.
(4) Assembl e the exhaust pi pe to the exhaust man-
i fol d and secure wi th bol ts, nuts and washers.
Ti ghten these nuts to 31 Nm (23 ft. l bs.) torque.
(5) Lower the vehi cl e.
(6) I nstal l the EGR tube (refer to Group 25, Emi s-
si on Control Systems).
CAUTION: The exhaust manifold heat shields
MUST be installed to protect the underhood compo-
nents.
(7) I nstal l the exhaust mani fol d heat shi el ds.
Ti ghten the nuts to 27 Nm (20 ft. l bs.) torque.
(8) Connect the negati ve cabl e to the battery.
CLEANING AND INSPECTION
INTAKE AND EXHAUST MANIFOLD4. 0L ENGINE
Cl ean the mati ng surfaces of the cyl i nder head and
the mani fol d i f the ori gi nal mani fol d i s to be
i nstal l ed.
INTAKE MANIFOLD 5. 2/5. 9L ENGINE
CLEANING
Cl ean mani fol d i n sol vent and bl ow dry wi th com-
pressed ai r.
Cl ean cyl i nder bl ock front and rear gasket surfaces
usi ng a sui tabl e sol vent.
The pl enum pan rai l must be cl ean and dry (free of
al l forei gn materi al ).
INSPECTION
I nspect mani fol d for cracks.
I nspect mati ng surfaces of mani fol d for fl atness
wi th a strai ghtedge.
EXHAUST MANIFOLD5. 2/5. 9L ENGINE
CLEANING
Cl ean mati ng surfaces on cyl i nder head and mani -
fol d, wash wi th sol vent and bl ow dry wi th com-
pressed ai r. I nspect mani fol d for cracks.
INSPECTION
I nspect mati ng surfaces of mani fol d for fl atness
wi th a strai ght edge. Seal surfaces must be fl at
wi thi n 0.1 mm (0.004 i nch) overal l .
Fig. 15 Exhaust Manifold Heat Shields (LeftShield
Shown)
FWD EXHAUST MANI- FOLD HEAT SHIELD
Fig. 16 Exhaust Manifold
STUD BOLT & WASHER EXHAUST MANIFOLD (RIGHT) BOLT & WASHER NUTS & WASHERS STUD BOLT & WASHER BOLT & WASHER STUD BOLT & WASHER STUD BOLT & WASHER EXHAUST MANIFOLD (LEFT)
ZG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE
Adjusting Strap
Bol ts . . . . . . . . . . . . . . . . . . . 23 Nm (200 i n. l bs.)
Catalytic Converter-to-Exhaust Pipe
U-bol t rod cl amp . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Exhaust Pipe-to-Manifold
Nuts . . . . . . . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Exhaust and Intake Manifold(4.0L)
Bol ts#15 & #811 . . . . . . . . . 33 Nm (24 ft. l bs.)
Exhaust Manifold Heat Shield(5.2/5.9L)
Nuts . . . . . . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Exhaust Manifold(4.0L)
Nuts #6 & 7 . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Exhaust Manifold(5.2/5.9L)
Nuts/Bol ts . . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Floor Pan Heat Shield
Bol ts/Nuts . . . . . . . . . . . . . . . . 5 Nm (45 i n. l bs.)
Generator Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Intake Manifold(5.2/5.9L)
Bol ts . . . . . . . . Refer to Procedure i n Thi s Secti on
Muffler-to-Catalytic Converter
U-bol t rod cl amp . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Oxygen Sensor
Sensor . . . . . . . . . . . . . . . . . . . 48 Nm (35 ft. l bs.)
PlenumPan(5.2/5.9L)
Bol ts . . . . . . . Refer to Procedure i n Thi s Secti on
Rear Tailpipe Hanger
Bol ts . . . . . . . . . . . . . . . . . . . 22 Nm (192 i n. l bs.)
Throttle Body
Bol ts/Nuts . . . . . . . . . . . . . . . 23 Nm (200 i n. l bs.)
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD ZG
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
EXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . . 1
REMOVAL AND INSTALLATION
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . 2
MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . 2
ENGINE EXHAUST MANIFOLD AND
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . 3
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
EXHAUST SYSTEM
The basi c exhaust system consi sts of an engi ne
exhaust mani fol d, exhaust pi pe, exhaust heat
shi el d(s), muffl er and exhaust tai l pi pe
The exhaust system uses a si ngl e muffl er.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. I f the sys-
tem contacts any body panel , i t may ampl i fy objec-
ti onabl e noi ses ori gi nati ng from the engi ne or body.
When i nspecti ng an exhaust system, cri ti cal l y
i nspect for cracked or l oose joi nts, stri pped screw or
bol t threads, corrosi on damage and worn, cracked or
broken hangers. Repl ace al l components that are
badl y corroded or damaged. DO NOT attempt to
repai r.
When repl acement i s requi red, use ori gi nal equi p-
ment parts (or equi val ent). Thi s wi l l assure proper
al i gnment and provi de acceptabl e exhaust noi se l ev-
el s.
CAUTION: Avoid application of rust prevention
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over-
spray near the edges is permitted. Application of
coating will result in excessive floor pan tempera-
tures and objectionable fumes.
EXHAUST HEAT SHIELDS
Exhaust heat shi el ds are needed to protect both
the vehi cl e and the envi ronment from the hi gh tem-
peratures (Fi g. 1).
DO NOT al l ow the engi ne to operate at fast i dl e for
extended peri ods (over 5 mi nutes). Thi s condi ti on
may resul t i n excessi ve temperatures i n the exhaust
system and on the fl oor pan.
Fig. 1 Heat Shields
ZG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
REMOVAL AND INSTALLATION
EXHAUST PIPE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Saturate the bol ts and nuts at turbo down pi pe
to exhaust pi pe wi th heat val ve l ubri cant. Al l ow 5
mi nutes for penetrati on.
(3) Di sconnect bol ts from exhaust pi pe to turbo
down pi pe (Fi g. 2).
(4) Remove the cl amp nuts at muffl er (Fi g. 3). To
remove the exhaust pi pe from the muffl er, appl y heat
unti l the metal becomes cherry red. Di sconnect the
exhaust pi pe from the muffl er. Remove the exhaust
pi pe.
INSTALLATION
(1) Assembl e exhaust pi pe to muffl er, l oosel y to
permi t proper al i gnment of al l parts.
(2) Connect the exhaust pi pe to the turbo down
pi pe mani fol d. Ti ghten the bol ts to 22.5 Nm torque.
(3) Use a new cl amp and ti ghten the nuts to 43
Nm torque.
(4) Lower the vehi cl e.
(5) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
MUFFLER AND EXHAUST TAILPIPE
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the front muffl er cl amp from the
exhaust pi pe and muffl er connecti on.
(3) Remove the rear exhaust tai l pi pe hanger cl amp
and remove the exhaust tai l pi pe from the front
exhaust tai l pi pe hanger.
(4) Remove the exhaust tai l pi pe assembl y from the
muffl er.
INSTALLATION
(1) I nstal l the muffl er onto the exhaust pi pe.
I nstal l the cl amp and ti ghten the nuts fi nger ti ght.
(2) I nstal l the exhaust tai l pi pe i nto the rear of the
muffl er.
(3) I nstal l the exhaust tai l pi pe/muffl er assembl y
on the rear exhaust tai l pi pe hanger. Make sure that
the exhaust tai l pi pe has suffi ci ent cl earance from the
fl oor pan.
(4) I nstal l the remai ni ng cl amps and the front
exhaust tai l pi pe hanger.
(5) Ti ghten the nuts on the muffl er-to-exhaust pi pe
cl amp to 43 Nm torque.
(6) Ti ghten the nuts on the muffl er-to-exhaust pi pe
cl amp to 43 Nm torque.
(7) Lower the vehi cl e.
(8) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
Fig. 2 Exhaust Down Pipe to Front Exhaust Pipe
Fig. 3 Front Pipe to Muffler
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD ZG
ENGINE EXHAUST MANIFOLD AND
TURBOCHARGER
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Remove ai r cl eaner hoses from turbocharger.
(3) Remove ai r cl eaner assembl y.
(4) Remove charge ai r cool er hoses from turbo-
charger and i ntake mani fol d.
(5) Remove al l components attached to the i ntake
mani fol d.
(6) Remove the EGR tube and EGR val ve.
(7) Remove exhaust mani fol d heat shi el d.
(8) Remove turbocharger oi l feed l i ne.
(9) Remove exhaust down pi pe from turbo.
(10) Rai se the vehi cl e
(11) Remove oi l drai n tube from turbocharger
(12) Lower the vehi cl e
(13) Remove turbocharger and exhaust mani fol d as
an assembl y.
CLEANING
Cl ean the exhaust mani fol d and cyl i nder head mat-
i ng surfaces.
INSTALLATION
(1) I nstal l turbocharger to exhaust mani fol d
ti ghten nuts to 27 Nm.
(2) I nstal l assembl y to engi ne, ti ghten nuts to 30
Nm.
(3) I nstal l oi l feed l i ne to turbocharger, ti ghten nut
to 26 Nm.
(4) I nstal l exhaust down pi pe to turbocharger,
ti ghten bol ts to 27 Nm.
(5) I nstal l exhaust heat shi el d, ti ghten bol ts to 11
Nm.
(6) Loose i nstal l EGR tube and EGR val ve to
i ntake mani fol d.
(7) I nstal l EGR val ve, ti ghten bol ts to 26 Nm.
(8) Ti ghten EGR tube nut to 26 Nm.
(9) Ti ghten EGR tube fl ange bol ts to 26 Nm.
(10) Connect al l components to i ntake mani fol d.
(11) Connect charge ai r cool er hoses to turbo-
charger and i ntake mani fol d.
(12) I nstal l ai r cl eaner assembl y.
(13) Connect ai r cl eaner hose to turbocharger.
(14) Rai se the vehi cl e
(15) I nstal l turbocharger drai n l i ne.
(16) Lower the vehi cl e
(17) Connect the battery negati ve cabl e.
(18) Start the engi ne and check for l eaks.
INTAKE MANIFOLD
REMOVAL
(1) Remove exhaust mani fol d and turbocharger
assembl y.
(2) Remove water mani fol d.
(3) Remove i ntake mani fol d.
CLEANING
Cl ean the i ntake mani fol d and cyl i nder head mat-
i ng surfaces. DO NOT allow foreign material to
enter either the intake manifold or the ports in
the cylinder head.
INSTALLATION
(1) I nstal l the new i ntake mani fol d gasket.
(2) Posi ti on the i ntake mani fol d i n pl ace and fi n-
ger ti ghten the mounti ng nuts.
(3) Ti ghten the fasteners i n sequence and to the
speci fi ed torque 30 Nm.
(4) Posi ti on the water mani fol d i n pl ace and fi nger
ti ghten the mounti ng nuts.
(5) Ti ghten the fasteners to the speci fi ed torque 12
Nm.
(6) I nstal l exhaust mani fol d and turbocharger
assembl y.
(7) I nstal l charge ai r cool er hose to i ntake mani -
fol d.
(8) Connect the battery negati ve cabl e.
(9) Start engi ne and check for l eaks.
ZG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE SPECIFICATIONS
Description Torque
EGR
Attachi ng Nuts . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
EGR
Tube Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
EGR
Tube Fl ange Bol ts . . . . . . . . . . . . . . . . . . . . . 26 Nm
Exhaust Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Exhaust Manifold
Heat Shi el d Nuts . . . . . . . . . . . . . . . . . . . . . 11 Nm
Exhaust Pipe
Support Cl amp Bol ts . . . . . . . . . . . . . . . . . 22.5 Nm
Exhaust Pipe
Support Cl amp Screw . . . . . . . . . . . . . . . . 22.5 Nm
Intake Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Muffler-to-Exhaust Pipe
Cl amp Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 43 Nm
Tail Pipe Clamp
Hanger bol t . . . . . . . . . . . . . . . . . . . . . . . . 22.5 Nm
Turbocharger-to-Exhaust manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
Turbocharger
Oi l Feed Li ne . . . . . . . . . . . . . . . . . . . . . . . 27.4 Nm
Turbocharger Down Pipe-to-Exhaust Pipe
Bol ts/Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 Nm
Turbocharger Down Pipe-to-Turbocharger
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD ZG
FRAME AND BUMPERS
CONTENTS
page page
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUMPERS
INDEX
page page
REMOVAL AND INSTALLATION
FRONT BUMPER/FASCIA . . . . . . . . . . . . . . . . . 1
REAR BUMPER FASCIA . . . . . . . . . . . . . . . . . . 2
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
FRONT BUMPER/FASCIA
REMOVAL
The Grand Cherokee front bumper i s actual l y a
bumper fasci a i ncorporated wi th a l ower wel ded
crossmember. The l ower crossmember i s a fi xed
wel ded structure. To repl ace the crossmember a
frame machi ne shoul d be used to correctl y al i gn the
crossmember to the uni body.
(1) Remove gri l l e screws at gri l l e openi ng rei n-
forcement (GOR) (Fi g. 1).
(2) I f equi pped, remove brush guard.
(3) Unsnap l ower cl i ps at gri l l e. Remove gri l l e
from (GOR).
(4) Remove turn si gnal s, si de markers and head-
l amps. Refer to Group 8L, Lamps for servi ce i nforma-
ti on.
(5) Remove the retai ners at the front fasci a (Fi g.
2).
(6) Remove the pl asti c ri vets at each front wheel
wel l (Fi g. 3).
(7) Sl i de the fasci a off of the retai ner pegs at the
si de of the fender attach brackets. Usi ng a smal l
screwdri ver, pul l up on l ocati ng tangs under turn si g-
nal mounti ng l ocati on.
(8) Remove the fasci a from the vehi cl e.
INSTALLATION
(1) Reverse removal procedure.
Fig. 1 Grille Removal
HOOD RELEASE CABLE HEADLAMP MOUNTING PANEL GRILLE OPENING REIN- FORCEMENT WITH HEAD- LAMPS GRILLE U-NUT
Fig. 2 Lower Fascia Removal
GRILLE OPENING REINFORCEMENT UPPER RETAIN- ERS LOWER RETAINERS FASCIA LOWER CROSS- MEMBER
ZG FRAME AND BUMPERS 13 - 1
REAR BUMPER FASCIA
REMOVAL
(1) Rai se and support the rear of the vehi cl e.
(2) Remove the upper scuff pad from fasci a.
(3) Remove the l ower retai ners from fasci a (Fi g. 5).
(4) Remove the push-i n retai ners l ocated at the
rear wheel wel l on each si de.
(5) Remove the fasci a from the bumper.
INSTALLATION
(1) Reverse the removal procedure.
REAR BUMPER
REMOVAL
(1) Remove trai l er hi tch, i f equi pped.
(2) Rai se and support the rear of the vehi cl e.
(3) Support the bumper.
(4) Remove push-i n retai ners at each si de rear
wheel wel l .
(5) Remove the bol ts that attach the bumper sup-
port brackets to the rear rai l s (Fi g. 4).
(6) Sl i de the bumper beam/fasci a off of the
retai ner pegs on the si de of the l ower quarter panel .
(7) Remove the beam/fasci a from the vehi cl e.
(8) Remove the bumper support brackets from the
bumper (Fi g. 5).
(9) Remove the upper scuff pad from the bumper
fasci a by squeezi ng fasteners and pushi ng through
sl ots.
(10) Remove the l ower retai ners from the bumper
fasci a.
(11) Remove the bumper fasci a from the bumper.
INSTALLATION
(1) I nstal l brackets onto bumper beam.
(2) I nstal l beam/brackets onto vehi cl e rai l s fi nger-
ti ght.
(3) I nstal l fasci a onto bumper assembl y.
(4) Check gaps and fi t. Adjust as necessary.
Ti ghten bol ts to 56 Nm (41 ft-l bs).
(5) I nstal l scuff pad.
(6) I f removed, i nstal l the trai l er hi tch.
Fig. 3 Wheel Well Retainers
FASCIA FASCIA RETAINERS
Fig. 4 Bumper Support Bracket
LOWER CROSSMEMBER SUPPORT BRACKET STUD
Fig. 5 Bumper Removal
BUMPER BRACKET SCUFF PLATE RETAINER REAR BUMPER FAS- CIA BUMPER BUMPER BRACKET
13 - 2 FRAME AND BUMPERS ZG
REMOVAL AND INSTALLATION (Continued)
FRAME
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
BRUSH GUARD . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . . 4
FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . . . . 3
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . 5
REAR TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . 5
TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSFER CASE SKID PLATE . . . . . . . . . . . . . 4
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 12
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . 6
GENERAL INFORMATION
GENERAL INFORMATION
Jeep Grand Cherokee vehi cl es do not have a con-
venti onal frame. They are constructed as a uni ti zed
body and frame. Jeep uni bodi es are constructed from
speci al hi gh-strength steel and coated metal s. Thi s
process reduces wei ght and provi des strength to
wi thstand the forces appl i ed agai nst structural mem-
bers. The structural members provi de a uni body that
has great structural strength.
REMOVAL AND INSTALLATION
FRONT TOW HOOK
REMOVAL
(1) Remove gri l l e and fasci a.
(2) Remove the nuts and bol ts that attach the tow
hooks to the l ower crossmember (Fi g. 1).
(3) Remove the tow hooks from the l ower cross-
member.
INSTALLATION
(1) Attach tow hook to bracket. Ti ghten nuts to 95
Nm (70 ft. l bs.) torque.
(2) Posi ti on tow eye bracket at crossmember.
I nsert bol ts thru the bracket and i nto the rei nforce-
ment.
(3) Posi ti on the tows hooks at the l ower crossmem-
ber.
(4) I nstal l stud pl ate from top of crossember, thru
the crossmember and bracket. Ti ghten al l nuts to 67
Nm (50 ft. l bs.) torque.
(5) I nstal l fasci a and gri l l e.
BRUSH GUARD
REMOVAL
(1) Remove the bol ts attachi ng the brush guard
(Fi g. 2) to brush guard brackets (Fi g. 3).
(2) Separate the brush guard from the vehi cl e.
INSTALLATION
(1) Posi ti on the brush guard on the vehi cl e.
(2) Loosel y i nstal l the bol ts attachi ng the brush
guard to brush guard brackets.
Fig. 1 Front Tow Hook
REINFORCEMENT TOWEYE TOW HOOK BRACKET
ZG FRAME AND BUMPERS 13 - 3
(3) Push the top of the brush guard i nward unti l i t
contacts the front fasci a.
(4) Ti ghten the bol ts to 28 Nm (20 ft. l bs.) torque.
FRONT SKID PLATE
REMOVAL
(1) Posi ti on a support under ski d pl ate.
(2) Remove the bol ts that attach ski d pl ate to
frame (Fi g. 4).
(3) Lower the ski d pl ate.
INSTALLATION
(1) Posi ti on the ski d pl ate on a support.
(2) Rai se i t i nto posi ti on
(3) I nstal l the bol ts. Ti ghten the bol ts to 54 Nm
(40 ft. l bs.) torque.
TRANSFER CASE SKID PLATE
REMOVAL
(1) Support ski d pl ate.
(2) Remove bol ts that attach ski d pl ate to trans-
mi ssi on support crossmember and frame si l l (Fi g. 5).
(3) Remove support and ski d pl ate from vehi cl e.
INSTALLATION
(1) I nstal l nutserts, i f removed.
(2) Posi ti on and support ski d pl ate at the frame
si l l and transmi ssi on support crossmember.
(3) Attach ski d pl ate to frame si l l and crossmem-
ber wi th the bol ts. Ti ghten bol ts to 27 Nm (20 ft. l bs)
torque.
Fig. 2 Brush Guard
BRUSH GUARD
TOW HOOK
Fig. 3 Brush Guard Bracket
REINFORCEMENT
CROSSMEMBER
REINFORCEMENT
Fig. 4 Front Skid Plate
UNDERBODY ASSEMBLY FRONT SKID PLATE FWD
Fig. 5 Transfer Case Skid
CROSSMEMBER FWD NUTSERT TRANSFER CASE SKID PLATE NUTSERT
13 - 4 FRAME AND BUMPERS ZG
REMOVAL AND INSTALLATION (Continued)
FUEL TANK SKID PLATE
REMOVAL
(1) Remove trai l er hi tch.
(2) Posi ti on a support under the fuel tank ski d
pl ate.
(3) Remove nuts attachi ng ski d pl ate to frame
rai l s (Fi g. 6).
(4) Lower ski d pl ate and remove support.
INSTALLATION
(1) Posi ti on ski d pl ate on a support and rai se i nto
posi ti on.
(2) I nstal l nuts attachi ng ski d pl ate to frame rai l s.
Ti ghten nuts to 74 Nm (55 ft. l bs.) torque.
(3) Remove support.
(4) I nstal l trai l er hi tch.
REAR TOW HOOK
REMOVAL
(1) Remove the nuts and bol ts that attach the tow
hook to the l ower crossmember (Fi g. 7).
(2) Remove the tow hook from the l ower cross-
member.
INSTALLATION
(1) Attach tow hook to bracket. Ti ghten nut to 95
Nm (70 ft. l bs.) torque.
(2) Posi ti on rei nforcement pl ate on top of body l i p.
(3) I nstal l the bol ts and nuts that attach tow hook.
Ti ghten nut to 95 Nm (70 ft. l bs.) torque.
TRAILER HITCH
REMOVAL
(1) I f necessary, remove trai l er tow wi re harness
connector from hi tch.
(2) Support hi tch.
(3) Remove nuts that attach the towi ng tube to
frame si l l s (Fi g. 8).
NOTE: Reinforcement brackets are retained on
frame sills with 4 studs.
(4) Remove bol ts from pl ate bracket and vehi cl e
rear crossmember. Lower support and hi tch.
Fig. 6 Fuel Tank Skid Plate
FRAME FWD SKID PLATE
Fig. 7 Rear Tow Hook
REINFORCEMENT BODY BRACKET REINFORCEMENT TOWHOOK
Fig. 8 Trailer Hitch
REAR HITCH STUDS HITCH
SKID PLATE BOLTS
FUEL TANK SKID PLATE
ZG FRAME AND BUMPERS 13 - 5
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Pl ace hi tch on a l i fti ng devi ce. Rai se, posi ti on
hi tch at proper l ocati on and support i t.
(2) Loosel y i nstal l nuts that attach towi ng tube to
vehi cl e frame si l l s.
(3) Posi ti on pl ate bracket and i nstal l attachi ng
bol ts through vehi cl e rear crossmember.
(4) Ti ghten al l attachi ng bol ts/nuts.
(5) Remove support and, i f removed, attach trai l er
wi re harness connector to hi tch.
SPECIFICATIONS
VEHICLE DIMENSIONS
Frame di mensi ons are l i sted i n metri c scal e. Al l
di mensi ons are from center to center of Pri nci pal
Locati ng Poi nt (PLP), or from center to center of PLP
and fastener l ocati on (Fi g. 9), (Fi g. 10), (Fi g. 11),
(Fi g. 12) and (Fi g. 13)
13 - 6 FRAME AND BUMPERS ZG
REMOVAL AND INSTALLATION (Continued)
Fig. 9 Vehicle DimensionsFront/SideView
A. & B. Center of radius at bottom to center of radius at top. C. Center of front door lower rear corner radius to center of A-pillar radius. D. Center of door hinge mount to center of door striker mount. E. Center of radius at bottom front to center of radius at top rear. F. Center of radius at bottom rear to center of radius at lower A-pillar.
ZG FRAME AND BUMPERS 13 - 7
SPECIFICATIONS (Continued)
Fig. 10 Vehicle DimensionsSide View
A. Quarter panel to Front Outer Body side upper and lower seam. B. Center of front upper door radius to center of rear lower door radius. C. Center of front lower door radius to center of rear upper door radius. D. Rear door hinge mount to rear door striker mount. A. Center of upper and lower rear quarter window opening. B. Center of radius front lower corner to center of radius rear upper corner. C. Center of radius front upper corner to center of radius rear lower corner.
13 - 8 FRAME AND BUMPERS ZG
SPECIFICATIONS (Continued)
Fig. 11 Vehicle DimensionsRear ViewAnd Engine Compartment
A. Center of upper liftgate opening to liftgate striker mount. B. & C. Center of radius upper corner to center of radius lower corner. D. Distance between outer quarter panel to tail lamp mounting panel to inner quarter panel seams.
ZG FRAME AND BUMPERS 13 - 9
SPECIFICATIONS (Continued)
Fig. 12 Frame DimensionsSide View
FRONT Top of Front Fender Bolt on Core Support. DATUM LINE OVERALL DATUM LENGTHS B to G = 1176mm G to J = 1265mm J to N = 1249mm HOLE DIAMETERS A = Bolt B = 14mm C = Front Fender Bolt D = Bolt E = Bolt F = Bolt G = 19mm x 25mm H = 19mm I = 19mm x 25mm J = 19mm K = Bolt L = Bolt M = Bolt N = 19mm x 25mm O = 13mm SIDE VIEW Datum Height Dimensions are PERPENDICULAR to Datum Plane. Datum Length Dimensions are PARALLEL to Centerline of Vehicle, and are Measured Center-to-Center.
13 - 10 FRAME AND BUMPERS ZG
SPECIFICATIONS (Continued)
Fig. 13 Frame DimensionsBottom View
All measurements in m BOTTOM VIEW BOTTOM VIEW POINT-TO-POINT DIMENSIONS ARE TAKEN WITH TRAM BAR POINTERS SET AT EQUAL LENGTHS. Bolts and Studs are Measured to Center. Holes are Measured to Closest Edge. DRIVER SIDE FRONT
ZG FRAME AND BUMPERS 13 - 11
SPECIFICATIONS (Continued)
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Front Tow Hook Nut . . . . . . . . . 100 Nm (74 ft. l bs.)
Front Ski d Pl ate Bol t . . . . . . . . . 54 Nm (40 ft. l bs.)
Fuel Tank Ski d Pl ate Nuts . . . . . 74 Nm (55 ft. l bs.)
Fuel Tank Ski d Pl ate Mtg Studs . 108 Nm (80 ft. l bs.)
Rear Bumper Bol t . . . . . . . . . . . 56 Nm (41 ft. l bs.)
Rear Tow Hook Nut . . . . . . . . . 100 Nm (74 ft. l bs.)
Trai l er Hi tch Nuts/Bol ts . . . . . . . 74 Nm (55 ft. l bs.)
Transfer Case Ski d Pl ate Bol ts . . 27 Nm (20 ft. l bs.)
13 - 12 FRAME AND BUMPERS ZG
SPECIFICATIONS (Continued)
FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . 3
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . 26
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . 1
GASOLINE/OXYGENATE BLENDS . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Throughout thi s group, references may be made to
a parti cul ar vehi cl e by l etter or number desi gnati on.
A chart showi ng the breakdown of these desi gnati ons
i s i ncl uded i n the I ntroducti on Secti on at the front of
thi s servi ce manual .
The Evaporati on Control System, i s al so consi dered
part of the fuel system. The system reduces the emi s-
si on of fuel vapor i nto the atmosphere.
The descri pti on and functi on of the Evaporati on
Control System i s found i n Group 25 of thi s manual .
FUEL REQUIREMENTS
Your vehi cl e was desi gned to meet al l emi ssi on reg-
ul ati ons and provi de excel l ent fuel economy when
usi ng hi gh qual i ty unl eaded gasol i ne.
Use unl eaded gasol i nes havi ng a mi ni mum posted
octane of 87.
I f your vehi cl e devel ops occasi onal l i ght spark
knock (pi ng) at l ow engi ne speeds thi s i s not harm-
ful . However; conti nued heavy knock at hi gh speeds
can cause damage and shoul d be reported to your
deal er i mmedi atel y. Engi ne damage as a resul t of
heavy knock operati on may not be covered by the
new vehi cl e warranty.
I n addi ti on to usi ng unl eaded gasol i ne wi th the
proper octane rati ng, those that contai n detergents,
corrosi on and stabi l i ty addi ti ves are recommended.
Usi ng gasol i nes that have these addi ti ves wi l l hel p
i mprove fuel economy, reduce emi ssi ons, and mai n-
tai n vehi cl e performance.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng, and stumbl e. I f you experi -
ence these probl ems, try another brand of gasol i ne
before consi deri ng servi ce for the vehi cl e.
GASOLINE/OXYGENATE BLENDS
Some fuel suppl i ers bl end unl eaded gasol i ne wi th
materi al s that contai n oxygen such as al cohol , MTBE
(Methyl Terti ary Butyl Ether) and ETBE (Ethyl Ter-
ti ary Butyl Ether). Oxygenates are requi red i n some
areas of the country duri ng wi nter months to reduce
carbon monoxi de emi ssi ons. The type and amount of
oxygenate used i n the bl end i s i mportant.
The fol l owi ng are general l y used i n gasol i ne
bl ends:
Ethanol - (Ethyl or Grai n Al cohol ) properl y
bl ended, i s used as a mi xture of 10 percent ethanol
and 90 percent gasol i ne. Gasol i ne bl ended wi th etha-
nol may be used i n your vehi cl e.
MTBE/ETBE - Gasol i ne and MTBE (Methyl Ter-
ti ary Butyl Ether) bl ends are a mi xture of unl eaded
gasol i ne and up to 15 percent MTBE. Gasol i ne and
ETBE (Ethyl Terti ary Butyl Ether) are bl ends of gas-
ol i ne and up to 17 percent ETBE. Gasol i ne bl ended
wi th MTBE or ETBE may be used i n your vehi cl e.
Methanol - Methanol (Methyl or Wood Al cohol ) i s
used i n a vari ety of concentrati ons bl ended wi th
unl eaded gasol i ne. You may encounter fuel s contai n-
i ng 3 percent or more methanol al ong wi th other
al cohol s cal l ed cosol vents.
DO NOT USE GASOLINES CONTAINING
METHANOL.
ZG FUEL SYSTEM 14 - 1
Use of methanol /gasol i ne bl ends may resul t i n
starti ng and dri veabi l i ty probl ems and damage cri ti -
cal fuel system components.
Probl ems that are the resul t of usi ng methanol /
gasol i ne bl ends are not the responsi bi l i ty of Chrysl er
Corporati on and may not be covered by the vehi cl e
warranty.
Reformulated Gasoline
Many areas of the country are requi ri ng the use of
cl eaner-burni ng fuel referred to as Reformulated
Gasoline . Reformul ated gasol i nes are speci al l y
bl ended to reduce vehi cl e emi ssi ons and i mprove ai r
qual i ty.
Chrysl er Corporati on strongl y supports the use of
reformul ated gasol i nes whenever avai l abl e. Al though
your vehi cl e was desi gned to provi de opti mum perfor-
mance and l owest emi ssi ons operati ng on hi gh qual -
i ty unl eaded gasol i ne, i t wi l l perform equal l y wel l
and produce even l ower emi ssi ons when operati ng on
reformul ated gasol i ne.
Materials Added to Fuel
I ndi scri mi nate use of fuel system cl eani ng agents
shoul d be avoi ded. Many of these materi al s i ntended
for gum and varni sh removal may contai n acti ve sol -
vents of si mi l ar i ngredi ents that can be harmful to
fuel system gasket and di aphragm materi al s.
14 - 2 FUEL SYSTEM ZG
GENERAL INFORMATION (Continued)
FUEL DELIVERY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . 3
FUEL FILTER/FUEL PRESSURE REGULATOR . . 4
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 4
FUEL INJECTORS4.0L ENGINE . . . . . . . . . . . 5
FUEL INJECTORS5.2L/5.9L ENGINES . . . . . . 5
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 4
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . 6
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . 6
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . 10
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . 10
FUEL PRESSURE LEAK DOWN TEST . . . . . . . . 9
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . 9
FUEL PUMP PRESSURE TEST5.2L/5.9L
ENGINES WITH PRESSURE TEST PORT . . . . 7
FUEL PUMP PRESSURE TEST5.2L/5.9L
ENGINES WITHOUT PRESSURE
TEST PORT . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL PUMP PRESSURE TEST4.0L ENGINE . . 7
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREWITHOUT PRESSURE TEST
PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREWITH PRESSURE TEST
PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL TUBES/LINES/HOSES AND CLAMPS . . . 11
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . 12
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . 23
FUEL FILTER/FUEL PRESSURE REGULATOR . 16
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . 18
FUEL INJECTOR RAIL4.0L ENGINE . . . . . . . 20
FUEL INJECTOR RAIL5.2L/5.9L ENGINES . . 18
FUEL INJECTOR(S) . . . . . . . . . . . . . . . . . . . . . 20
FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . 17
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . 17
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . 22
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . 23
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . 24
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . 24
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 25
VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
The fuel del i very system consi sts of:
the fuel pump modul e contai ni ng the el ectri c
fuel pump, fuel fi l ter/fuel pressure regul ator, fuel
gauge sendi ng uni t (fuel l evel sensor) and a separate
fuel fi l ter l ocated at bottom of pump modul e
fuel tubes/l i nes/hoses
qui ck-connect fi tti ngs
fuel i njector rai l
fuel i njectors
fuel tank
fuel tank fi l l er/vent tube assembl y
fuel tank fi l l er tube cap
accel erator pedal
throttl e cabl e
Fuel i s returned through the fuel pump modul e
and back i nto the fuel tank through the fuel fi l ter/
fuel pressure regul ator. A separate fuel return l i ne
from the engi ne to the tank i s not used.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock-
nut/gasket, and rol l over val ve (refer to Group 25,
Emi ssi on Control System for rol l over val ve i nforma-
ti on).
A fuel fi l l er/vent tube assembl y consi sti ng of a
pressure-vacuum fi l l er cap i s used.
Al so to be consi dered part of the fuel system i s the
evaporati on control system contai ni ng the pressure
rel i ef/rol l over val ve. Thi s i s desi gned to reduce the
emi ssi on of fuel vapors i nto the atmosphere. The
descri pti on and functi on of the Evaporati ve Control
System i s found i n Group 25, Emi ssi on Control Sys-
tems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
ZG FUEL SYSTEM 14 - 3
FUEL PUMP MODULE
The fuel pump modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 1) or (Fi g. 2). The fuel pump modul e
contai ns the fol l owi ng components:
A combi nati on fuel fi l ter/fuel pressure regul ator
A separate fuel pi ck-up fi l ter (strai ner)
An el ectri c fuel pump
A threaded l ocknut to retai n modul e to tank
Fuel gauge sendi ng uni t (fuel l evel sensor)
Fuel suppl y tube (l i ne) connecti on
The fuel gauge sendi ng uni t, pi ck-up fi l ter and fuel
fi l ter/fuel pressure regul ator may be servi ced sepa-
ratel y. I f the el ectri cal fuel pump requi res servi ce,
the enti re fuel pump modul e must be repl aced.
FUEL PUMP
The fuel pump used i n thi s system has a perma-
nent magnet el ectri c motor. The pump i s part of the
fuel pump modul e. Fuel i s drawn i n through a fi l ter
at the bottom of the modul e and pushed through the
el ectri c motor gearset to the pump outl et.
Check Valve Operation: The pump outl et con-
tai ns a one-way check val ve to prevent fuel fl ow back
i nto the tank and to mai ntai n fuel suppl y l i ne pres-
sure (engi ne warm) when pump i s not operati onal . I t
i s al so used to keep the fuel suppl y l i ne ful l of gaso-
l i ne when pump i s not operati onal . After the vehi cl e
has cool ed down, fuel pressure may drop to 0 psi
(col d fl ui d contracts), but l i qui d gasol i ne wi l l remai n
i n fuel suppl y l i ne between the check val ve and fuel
i njectors. Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition. Refer to the Fuel Pressure Leak
Down Test i n thi s group for more i nformati on.
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
FUEL GAUGE SENDING UNIT
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e (Fi g. 2).
The sendi ng uni t consi sts of a fl oat, an arm, and a
vari abl e resi stor (track). The resi stor track i s used to
send el ectri cal si gnal s to the Powertrai n Control
Modul e (PCM) for fuel gauge operati on and for OBD
I I emi ssi on requi rements.
For fuel gauge operation: As fuel l evel
i ncreases, the fl oat and arm move up. Thi s decreases
the sendi ng uni t resi stance, causi ng the fuel gauge to
read ful l . As fuel l evel decreases, the fl oat and arm
move down. Thi s i ncreases the sendi ng uni t resi s-
tance causi ng the fuel gauge to read empty.
After thi s fuel l evel si gnal i s sent to the PCM, the
PCM wi l l transmi t the data across the CCD bus ci r-
cui ts to the i nstrument panel . Here i t i s transl ated
i nto the appropri ate fuel gauge l evel readi ng.
For OBD II emission requirements: The vol tage
si gnal i s sent from the resi stor track to the PCM to
i ndi cate fuel l evel . The purpose of thi s feature i s to
prevent a fal se setti ng of mi sfi re and fuel system
moni tor troubl e codes. Thi s i s i f the fuel l evel i n the
tank i s l ess than approxi matel y 15 percent, or more
than approxi matel y 85 percent of i ts rated capaci ty.
FUEL FILTER/FUEL PRESSURE REGULATOR
A combi nati on fuel fi l ter and fuel pressure regul a-
tor i s used on al l engi nes. I t i s l ocated on the top of
fuel pump modul e (Fi g. 1). A separate frame mounted
fuel fi l ter i s not used wi th any engi ne.
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the Powertrai n Control
Modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 kPa 34
kPa (49.2 psi 5 psi ) at the fuel i njectors. I t con-
Fig. 1 Fuel Tank/Fuel Pump Module (Top View)
FRONT
ALIGNMENT ARROW (12 OCLOCK)
Fig. 2 Fuel Pump Module Components
FUEL GAUGE FLOAT
PICK-UP FILTER
FUEL GAUGE SENDING UNIT
14 - 4 FUEL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
tai ns a di aphragm, cal i brated spri ngs and a fuel
return val ve. The i nternal fuel fi l ter i s al so part of
the assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump through an openi ng tube at the bot-
tom of fi l ter/regul ator (Fi g. 3).
The regul ator acts as a check val ve to mai ntai n
some fuel pressure when the engi ne i s not operati ng.
Thi s wi l l hel p to start the engi ne. A second check
val ve i s l ocated at the outl et end of the el ectri c fuel
pump. Refer to Fuel PumpDescription and
Operation for more information. Also refer to
the Fuel Pressure Leak Down Test and the Fuel
Pump Pressure Tests.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 49 psi , an i nternal di aphragm cl oses
and excess fuel i s routed back i nto the tank through
the pressure regul ator. A separate fuel return l i ne i s
not used.
FUEL TANK
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
Al l model s have a pressure rel i ef/rol l over val ve
mounted on the top of the fuel tank.
An evaporati ve control system i s used to reduce
emi ssi ons of fuel vapors i nto atmosphere by evapora-
ti on and to reduce unburned hydrocarbons emi tted
by vehi cl e engi ne. When fuel evaporates from fuel
tank, vapors pass through vent hoses or tubes to a
charcoal cani ster. The vapors are temporari l y hel d i n
the cani ster. When the engi ne i s runni ng, the vapors
are drawn i nto i ntake mani fol d. Refer to Group 25,
Emi ssi on Control System for addi ti onal i nformati on.
ROLLOVER VALVE(S)
Refer to Group 25, Emi ssi on Control System for
i nformati on.
FUEL INJECTORS 5. 2L/5. 9L ENGINES
The fuel i njectors are attached to the fuel rai l (Fi g.
4). 5.2L V-8 engi nes use ei ght i njectors.
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
FUEL INJECTORS 4. 0L ENGINE
Si x i ndi vi dual fuel i njectors are used wi th the 4.0L
6-cyl i nder engi ne. The i njectors are attached to the
fuel rai l (Fi g. 5).
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
Fig. 3 Fuel Filter/Fuel Pressure Regulator
FUEL FILTER/FUEL PRES- SURE REGULATOR
TO FUEL INJECTORS
Fig. 4 Fuel Injectors5.2L5.9LEnginesTypical
FUEL RAIL FUEL INJECTOR HAR- NESS CONNECTORS FUEL INJECTOR
ZG FUEL SYSTEM 14 - 5
DESCRIPTION AND OPERATION (Continued)
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Duri ng start up, battery vol tage i s suppl i ed to the
i njectors through the ASD rel ay. When the engi ne i s
operati ng, vol tage i s suppl i ed by the chargi ng sys-
tem. The PCM determi nes i njector pul se wi dth based
on vari ous i nputs.
FUEL RAIL
The fuel rai l suppl i es the necessary fuel to each
i ndi vi dual fuel i njector and i s mounted to the i ntake
mani fol d. The fuel pressure regul ator i s no l onger
mounted to the fuel rai l on any engi ne. I t i s now
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Pressure Regul ator i n thi s group for
i nformati on.
Certai n engi nes are equi pped wi th a fuel pressure
test port. Not all engines are equipped with this
test port.
The fuel rai l i s not repai rabl e.
CAUTION: 5.2L/5.9L Engines Only: The left and
right sections of the fuel rail are connected with a
flexible connecting hose. Do not attempt to sepa-
rate the rail halves at this connecting hose. Due to
the design of this connecting hose, it does not use
any clamps. Never attempt to install a clamping
device of any kind to the hose. When removing the
fuel rail assembly for any reason, be careful not to
bend or kink the connecting hose.
FUEL TANK FILLER TUBE CAP
The l oss of any fuel or vapor out of fi l l er neck i s
prevented by the use of a pressure-vacuum fuel tank
fi l l er tube cap. Rel i ef val ves i nsi de cap wi l l rel ease
onl y under si gni fi cant pressure of 6.58 to 8.44 kPa
(1.95 to 2.5 psi ). The vacuum rel ease for al l fuel fi l l er
tube caps i s between .97 and 5.0 kPa (.14 and .72
psi ). Thi s cap must be repl aced by a si mi l ar uni t i f
repl acement i s necessary. Thi s i s i n order for the sys-
tem to remai n effecti ve.
CAUTION: Remove fuel tank filler tube cap before
servicing any fuel system component. This is done
to help relieve tank pressure.
QUICK-CONNECT FITTINGS
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type or a pl asti c retai ner
ri ng type. Some are equi pped wi th safety l atch cl i ps.
Refer to the Removal /I nstal l ati on secti on for more
i nformati on.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fig. 5 Fuel Injectors4.0L Engine
FUEL PRESSURE TEST PORT (IF EQUIPPED) FUEL INJECTOR NUMBEREDTAG FUEL RAIL FUEL RAIL MOUNTING BOLTS
Fig. 6 Fuel RailTypical(5.2L/5.9L Engine Shown)
FUEL RAIL CONNECTING HOSE
FUEL RAIL
14 - 6 FUEL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
FUEL PUMP PRESSURE TEST4. 0L ENGINE
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test and Fuel Pressure Leak Down Test
found el sewhere i n thi s group.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately ri se to speci fi cati on.
NOTE: The fuel pressure test port is used on cer-
tain engines only. If equipped, the test port will be
located on the fuel rail (Fig. 7). A sealing cap is
screwed onto the test port.
Al l fuel systems are equi pped wi th a fuel tank
modul e mounted, combi nati on fuel fi l ter/fuel pressure
regul ator. The fuel pressure regul ator i s not con-
trol l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove the protecti ve cap at the fuel rai l test
port. Connect the 0414 kPa (0-60 psi ) fuel pressure
gauge (from gauge set 5069) to the test port pressure
fi tti ng on the fuel rai l .
(2) Start and warm the engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa 34
kPa (49.2 psi 5 psi ) at i dl e.
(3) I f engi ne runs but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, repl ace fuel pump modul e assembl y. Refer to
Fuel Pump Modul e Removal /I nstal l ati on.
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on.
FUEL PUMP PRESSURE TEST 5. 2L/5. 9L
ENGINES WITH PRESSURE TEST PORT
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test and Fuel Pressure Leak Down Test
found el sewhere i n thi s group.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately ri se to speci fi cati on.
NOTE: The fuel pressure test port is used on cer-
tain engines only. On 5.2L/5.9L engines, and when
equipped, the test port will be located on the fuel
rail near the throttle position sensor (Fig. 8). A seal-
ing cap is screwed onto the test port.
Al l fuel systems are equi pped wi th a fuel tank
modul e mounted, combi nati on fuel fi l ter/fuel pressure
regul ator. The fuel pressure regul ator i s not con-
trol l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
Fig. 7 Fuel Pressure Test Port4.0LEngine
FUEL PRESSURE TEST PORT (IF EQUIPPED) FUEL INJECTOR NUMBEREDTAG FUEL RAIL FUEL RAIL MOUNTING BOLTS
ZG FUEL SYSTEM 14 - 7
(1) Remove the protecti ve cap at the fuel rai l test
port. Connect the 0414 kPa (0-60 psi ) fuel pressure
gauge (from gauge set 5069) to the test port pressure
fi tti ng on the fuel rai l (Fi g. 8).
(2) Start and warm the engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa 34
kPa (49.2 psi 5 psi ) at i dl e.
(3) I f engi ne runs but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, repl ace fuel pump modul e assembl y. Refer to
Fuel Pump Modul e Removal /I nstal l ati on.
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on.
FUEL PUMP PRESSURE TEST 5. 2L/5. 9L
ENGINES WITHOUT PRESSURE TEST PORT
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test and Fuel Pressure Leak Down Test
found el sewhere i n thi s group.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately ri se to speci fi cati on.
NOTE: The fuel pressure test port is used on cer-
tain 5.2L/5.9L engines only. If equipped, the test
port will be located on the fuel rail near the throttle
position sensor. If not equipped, refer to the follow-
ing procedure:
Al l fuel systems are equi pped wi th a fuel tank
modul e mounted, combi nati on fuel fi l ter/fuel pressure
regul ator. The fuel pressure regul ator i s not con-
trol l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Rel ease fuel pressure. Refer to the Fuel System
Pressure Rel ease ProcedureWi thout Pressure Test
Port.
(2) Di sconnect l atch cl i p and fuel l i ne at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures. Thi s
can be found i n thi s secti on of the group.
(3) Connect adapter tool number 6923 i nto the fuel
rai l (Fi g. 9). Be sure adapter tool is fully seated
into fuel rail.
Fig. 8 Fuel Pressure Test Port5.2L/5.9LEngines
Typical
FUEL PRESSURE TEST HOSE FUEL PRESSURE TEST GAUGE FUEL RAIL TEST PORT
Fig. 9 Installing Adapter Tool and PressureGauge
VEHICLE FUEL LINE TEST PORT T SPECIAL TOOL6923 FUEL PRES- SURE TEST GAUGE LATCH CLIP FUEL RAIL
14 - 8 FUEL SYSTEM ZG
DIAGNOSIS AND TESTING (Continued)
(4) I nstal l l atch cl i p to fuel rai l . I f l atch cl i p can
not be ful l y seated i nto fuel rai l , check for adapter
tool not ful l y seated to fuel rai l .
(5) Connect vehi cl e fuel l i ne i nto adapter tool 6923
(Fi g. 9). Be sure fuel l i ne i s ful l y seated i nto adapter
tool 6923.
(6) Remove protecti ve cap at test port T on
adapter tool number 6923.
(7) Connect the 0414 kPa (0-60 psi ) fuel pressure
gauge (from gauge set 5069) to the test port T (Fi g.
9).
(8) Start and warm the engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa 34
kPa (49.2 psi 5 psi ) at i dl e.
(9) I f engi ne runs but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, repl ace fuel pump modul e assembl y. Refer to
Fuel Pump Modul e Removal /I nstal l ati on.
(10) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on.
(11) After performi ng pressure test, i nstal l fuel
l i ne i nto fuel rai l . I nstal l l atch cl i p i nto fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures. Thi s
can be found i n thi s secti on of the group.
FUEL PUMP CAPACITY TEST
Before performing this test, verify fuel pump
pressure by performing the Fuel Pump Pres-
sure Test. Use this test in conjunction with the
Fuel Pressure Leak Down Test found elsewhere
in this group.
(1) Rel ease fuel system pressure. Refer to the Fuel
Pressure Rel ease Procedure i n thi s group.
(2) Di sconnect fuel suppl y l i ne at fuel rai l . Refer to
Qui ck-Connect Fi tti ngs i n the Servi ce Procedures
secti on of thi s group for procedures. Some engi nes
may requi re ai r cl eaner housi ng removal before l i ne
di sconnecti on.
(3) Connect appropri ate Fuel Li ne Pressure Test
Adapter Tool Hose (number 6631, 6923, 6541 or
6539) i nto di sconnected fuel suppl y l i ne. I nsert other
end of Adaptor Tool hose i nto a graduated contai ner.
(4) Remove fuel fi l l cap.
(5) To acti vate fuel pump and pressuri ze system,
obtai n DRB scan tool and actuate ASD Fuel System
Test.
(6) A good fuel pump wi l l del i ver at l east 1/4 l i ter
of fuel i n 7 seconds. Do not operate fuel pump for
l onger than 7 seconds wi th fuel l i ne di sconnected as
fuel pump modul e reservoi r may run empty.
(a) I f capaci ty i s l ower than speci fi cati on, but
fuel pump can be heard operati ng through fuel fi l l
cap openi ng, check for a ki nked/damaged fuel sup-
pl y l i ne somewhere between fuel rai l and fuel
pump modul e.
(b) I f l i ne i s not ki nked/damaged, and fuel pres-
sure i s OK, but capaci ty i s l ow, repl ace fuel fi l ter/
fuel pressure regul ator. The fi l ter/regul ator may be
servi ced separatel y on certai n appl i cati ons. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for addi ti onal i nformati on.
(c) I f both fuel pressure and capaci ty are l ow,
repl ace fuel pump modul e assembl y. Refer to Fuel
Pump Modul e Removal /I nstal l ati on.
FUEL PRESSURE LEAK DOWN TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Pressure Test and Fuel Pump Capaci ty Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately ri se to speci fi cati on.
Abnormal l y l ong peri ods of cranki ng to restart a
hot engi ne that has been shut down for a short
peri od of ti me may be caused by:
Fuel pressure bl eedi ng past a fuel i njector(s).
Fuel pressure bl eedi ng past the check val ve i n
the fuel pump modul e.
(1) Di sconnect the fuel i nl et l i ne at fuel rai l . Refer
to Fuel Tubes/Li nes/Hoses and Cl amps i n thi s secti on
of the group for procedures. On some engi nes, ai r
cl eaner housi ng removal may be necessary before
fuel l i ne di sconnecti on.
(2) Connect the appropri ate Fuel Li ne Pressure
Test Adapter Tool (number 6539, 6631, 6541 or 6923)
between the di sconnected fuel l i ne and fuel rai l (Fi g.
10) or (Fi g. 11).
(3) Connect the 0-414 kPa (0-60 psi ) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropri ate Adaptor Tool . The fittings on both
tools must be in good condition and free from
any small leaks before performing the proceed-
ing test.
(4) Start engi ne and bri ng to normal operati ng
temperature.
(5) Observe test gauge. Normal operati ng pressure
shoul d be 339 kPa 34 kPa (49.2 psi 5 psi ).
(6) Shut engi ne off.
ZG FUEL SYSTEM 14 - 9
DIAGNOSIS AND TESTING (Continued)
(7) Pressure shoul d not fal l bel ow 30 psi for five
minutes.
(8) I f pressure fal l s bel ow 30 psi , i t must be deter-
mi ned i f a fuel i njector, the check val ve wi thi n the
fuel pump modul e, or a fuel tube/l i ne i s l eaki ng.
(9) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(10) Shut engi ne off.
(11) Testing for fuel injector or fuel rail leak-
age: Cl amp off the rubber hose porti on of Adaptor
Tool between the fuel rai l and the test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a fuel i njector or the fuel rai l i s l eaki ng.
(12) Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Cl amp off the rubber hose porti on of Adaptor Tool
between the vehi cl e fuel l i ne and test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a l eak may be found at a fuel tube/l i ne. I f no
l eaks are found at fuel tubes or l i nes, one of the
check val ves i n ei ther the el ectri c fuel pump or fi l ter/
regul ator may be l eaki ng.
Note: A qui ck l oss of pressure usual l y i ndi cates a
defecti ve check val ve i n the fi l ter/regul ator. A sl ow
l oss of pressure usual l y i ndi cates a defecti ve check
val ve i n the el ectri c fuel pump.
The el ectri c fuel pump i s not servi ced separatel y.
Repl ace the fuel pump modul e assembl y. The fi l ter/
regul ator may be repl aced separatel y on certai n
appl i cati ons. Refer to Fuel Fi l ter/Fuel Pressure Reg-
ul ator Removal /I nstal l ati on for addi ti onal i nforma-
ti on.
FUEL GAUGE SENDING UNIT
The fuel gauge sendi ng uni t contai ns a vari abl e
resi stor (track). As the fl oat moves up or down, el ec-
tri cal resi stance wi l l change. Refer to Group 8E,
I nstrument Panel and Gauges for Fuel Gauge test-
i ng. To test the gauge sendi ng uni t onl y, i t must be
removed from vehi cl e. The uni t i s part of the fuel
pump modul e. Refer to Fuel Pump Modul e Removal /
I nstal l ati on for procedures. Measure the resi stance
across the sendi ng uni t termi nal s. Wi th fl oat i n up
posi ti on, resi stance shoul d be 20 ohms. Wi th fl oat i n
down posi ti on, resi stance shoul d be 220 ohms.
FUEL INJECTOR TEST
To perform a compl ete test of the fuel i njectors and
thei r ci rcui try, refer to DRB scan tool and appropri -
ate Powertrai n Di agnosti cs Procedures manual . To
test the i njector onl y, refer to the fol l owi ng:
Di sconnect the fuel i njector wi re harness connector
from the i njector. Pl ace an ohmmeter across the
i njector el ectri cal termi nal s. Resi stance readi ng
shoul d be approxi matel y 12 ohms 1.2 ohms at 20C
(68F).
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREWITH PRESSURE TEST PORT
NOTE: The fuel pressure test port is used on cer-
tain engines only. If equipped, the test port will be
located on the fuel rail near the throttle position
sensor. A sealing cap is screwed onto the test port.
The fuel system i s under constant fuel pressure
(even wi th the engi ne off).
Fig. 10 Connecting Adapter ToolTypical
FUEL PRESSURE TEST GAUGE
FUEL RAIL
FUEL LINE (TO TANK) ADAPTER TOOL #6539 OR #6631
Fig. 11 Connecting Adapter ToolTypical
VEHICLE FUEL LINE TEST PORT T SPECIAL TOOL6923 FUEL PRES- SURE TEST GAUGE LATCH CLIP FUEL RAIL
14 - 10 FUEL SYSTEM ZG
DIAGNOSIS AND TESTING (Continued)
WARNING: BECAUSE THE FUEL SYSTEM IS
UNDER CONSTANT FUEL PRESSURE, THE PRES-
SURE MUST BE RELEASED BEFORE SERVICING
ANY FUEL SYSTEM COMPONENT. THIS DOES NOT
APPLY TO THROTTLE BODY REMOVAL.
(1) Di sconnect negati ve battery cabl e.
(2) Remove the fuel tank fi l l er tube cap to rel ease
fuel tank pressure.
(3) Remove protecti ve cap from pressure test port
on the fuel rai l . Thi s i s l ocated on top of fuel rai l
near the throttl e posi ti on sensor.
WARNING: DO NOT ALLOW FUEL TO SPILL ONTO
THE ENGINE INTAKE OR EXHAUST MANIFOLDS.
PLACE SHOP TOWELS UNDER AND AROUND THE
PRESSURE PORT TO ABSORB FUEL WHEN THE
PRESSURE IS RELEASED FROM THE FUEL RAIL.
WARNING: WEAR PROPER EYE PROTECTION
WHEN RELEASING FUEL SYSTEM PRESSURE.
(4) Obtai n the fuel pressure gauge/hose assembl y
from fuel pressure gauge tool set 5069. Remove the
gauge from the hose.
(5) Pl ace one end of hose (gauge end) i nto an
approved gasol i ne contai ner.
(6) Pl ace a shop towel under the test port.
(7) To rel ease fuel pressure, screw the other end of
hose onto the fuel pressure test port.
(8) After fuel pressure has been rel eased, remove
the hose from the test port.
(9) I nstal l protecti ve cap to fuel test port.
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE WITHOUT PRESSURE TEST PORT
Use the following procedure if the fuel rail is
not equipped with a fuel pressure test port.
(1) Remove the Fuel Pump rel ay from the Power
Di stri buti on Center (PDC). For l ocati on of the rel ay,
refer to the l abel on the undersi de of the PDC cover.
(2) Start and run engi ne unti l i t stal l s.
(3) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(4) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within the fuel rail.
Do not attempt to use the following steps to relieve
this pressure as excessive fuel will be forced into a
cylinder chamber.
(5) Unpl ug connector from any i njector.
(6) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(7) Connect the other end of the jumper wi re to
the posi ti ve si de of the battery.
(8) Connect one end of a second jumper wi re to the
remai ni ng i njector termi nal .
CAUTION: Supplying power to an injector for more
than 4 seconds will permanently damage the injec-
tor. Do not leave the injector connected to power
for more than 4 seconds.
(9) Momentari l y touch the other end of thi s
jumper wi re to the negati ve termi nal of the battery
for no more than 4 seconds.
(10) Pl ace a rag or towel bel ow the fuel l i ne at the
qui ck connect to the rai l .
(11) Di sconnect the qui ck connect fi tti ng to the
rai l . Refer to Qui ck-Connect Fi tti ngs i n thi s secti on.
(12) Return the fuel pump rel ay to the PDC.
(13) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n the PCM memory due to
fuel pump rel ay removal . The DRB scan tool must be
used to erase a DTC. Refer to Group 25, Emi ssi on
Control System. See On-Board Di agnosti cs.
FUEL TUBES/LINES/HOSES AND CLAMPS
Al so refer to the secti on on Qui ck-Connect Fi tti ngs.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
I nspect al l hose connecti ons such as cl amps, cou-
pl i ngs and fi tti ngs to make sure they are secure and
l eaks are not present. The component shoul d be
repl aced i mmedi atel y i f there i s any evi dence of deg-
radati on that coul d resul t i n fai l ure.
Fig. 12 Fuel Injector Internal ComponentsTypical
SEAT- GUIDE NEEDLE BODY EYELET SEAL WIRE BOBBINELECTRICAL TERMINAL PLASTIC CONNEC- TOR
FUEL
INLET
FILTER RETAINER SEAL INLET TUBE SEAL SPRING HOUSING ARMATURE SPACER SEAL SEAL BACK-UP WASHER FUEL OUTLET ORI- FICEDISC
ZG FUEL SYSTEM 14 - 11
SERVICE PROCEDURES (Continued)
Never attempt to repai r a pl asti c fuel l i ne/tube.
Repl ace as necessary.
Avoi d contact of any fuel tubes/hoses wi th other
vehi cl e components that coul d cause abrasi ons or
scuffi ng. Be sure that the pl asti c fuel l i nes/tubes are
properl y routed to prevent pi nchi ng and to avoi d heat
sources.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
The hose cl amps used to secure rubber hoses on
fuel i njected vehi cl es are of a speci al rol l ed edge con-
structi on. Thi s constructi on i s used to prevent the
edge of the cl amp from cutti ng i nto the hose. Onl y
these rol l ed edge type cl amps may be used i n thi s
system. Al l other types of cl amps may cut i nto the
hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
Ti ghten hose cl amps to 1 Nm (15 i n. l bs.) torque.
QUICK-CONNECT FITTINGS
Al so refer to the Fuel Tubes/Li nes/Hoses and
Cl amps secti on.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type, a pl asti c retai ner ri ng
type or a l atch cl i p type. Certai n fi tti ngs may requi re
the use of a speci al tool for di sconnecti on.
SINGLE-TAB TYPE
Thi s type of fi tti ng i s equi pped wi th a si ngl e pul l
tab (Fi g. 13). The tab i s removabl e. After the tab i s
removed, the qui ck-connect fi tti ng can be separated
from the fuel system component.
CAUTION: The interior components (o-rings, spac-
ers) of this type of quick-connect fitting are not ser-
viced separately, but new pull tabs are available. Do
not attempt to repair damaged fittings or fuel lines/
tubes. If repair is necessary, replace the complete
fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
DISCONNECTION/CONNECTION
(1) Di sconnect negati ve battery cabl e from battery.
(2) Perform the fuel pressure rel ease procedure.
Refer to the Fuel Pressure Rel ease Procedure i n thi s
secti on.
(3) Cl ean the fi tti ng of any forei gn materi al before
di sassembl y.
(4) Press the rel ease tab on the si de of fi tti ng to
rel ease pul l tab (Fi g. 14).
CAUTION: If this release tab is not pressed prior
to releasing the pull tab, the pull tab will be dam-
aged.
(5) Whi l e pressi ng the rel ease tab on the si de of
the fi tti ng, use a screwdri ver to pry up the pul l tab
(Fi g. 14).
(6) Rai se the pul l tab unti l i t separates from the
qui ck-connect fi tti ng (Fi g. 15). Di scard the ol d pul l
tab.
(7) Di sconnect the qui ck-connect fi tti ng from the
fuel system component bei ng servi ced.
(8) I nspect the qui ck-connect fi tti ng body and fuel
system component for damage. Repl ace as necessary.
Fig. 13 Single-Tab Type Fitting
PULL TAB QUICK-CONNECT FITTING PRESS HERE TO REMOVE PULL TAB INSERTED TUBE END
Fig. 14 Disconnecting Single-Tab Type Fitting
PULL TAB SCREWDRIVER QUICK-CONNECT FITTING
14 - 12 FUEL SYSTEM ZG
SERVICE PROCEDURES (Continued)
(9) Pri or to connecti ng the qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean the parts wi th a l i nt-free
cl oth. Lubri cate them wi th cl ean engi ne oi l .
(10) I nsert the qui ck-connect fi tti ng i nto the fuel
tube or fuel system component unti l the bui l t-on stop
on the fuel tube or component rests agai nst back of
fi tti ng.
(11) Obtai n a new pul l tab. Push the new tab
down unti l i t l ocks i nto pl ace i n the qui ck-connect fi t-
ti ng.
(12) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(13) Connect negati ve cabl e to battery.
(14) Start engi ne and check for l eaks.
TWO-TAB TYPE FITTING
Thi s type of fi tti ng i s equi pped wi th tabs l ocated on
both si des of the fi tti ng (Fi g. 16). These tabs are sup-
pl i ed for di sconnecti ng the qui ck-connect fi tti ng from
component bei ng servi ced.
CAUTION: The interior components (o-rings, spac-
ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
DISCONNECTION/CONNECTION
(1) Di sconnect negati ve battery cabl e from the bat-
tery.
(2) Perform the fuel pressure rel ease procedure.
Refer to the Fuel Pressure Rel ease Procedure i n thi s
secti on.
(3) Cl ean the fi tti ng of any forei gn materi al before
di sassembl y.
(4) To di sconnect the qui ck-connect fi tti ng, squeeze
the pl asti c retai ner tabs (Fi g. 16) agai nst the si des of
the qui ck-connect fi tti ng wi th your fi ngers. Tool use
i s not requi red for removal and may damage pl asti c
retai ner. Pul l the fi tti ng from the fuel system compo-
nent bei ng servi ced. The pl asti c retai ner wi l l remai n
on the component bei ng servi ced after fi tti ng i s di s-
connected. The o-ri ngs and spacer wi l l remai n i n the
qui ck- connect fi tti ng connector body.
(5) I nspect the qui ck-connect fi tti ng body and com-
ponent for damage. Repl ace as necessary.
CAUTION: When the quick-connect fitting was dis-
connected, the plastic retainer will remain on the
component being serviced. If this retainer must be
removed, very carefully release the retainer from
the component with two small screwdrivers. After
removal, inspect the retainer for cracks or any dam-
age.
(6) Pri or to connecti ng the qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean the parts wi th a l i nt-free
cl oth. Lubri cate them wi th cl ean engi ne oi l .
(7) I nsert the qui ck-connect fi tti ng to the compo-
nent bei ng servi ced and i nto the pl asti c retai ner.
When a connecti on i s made, a cl i ck wi l l be heard.
(8) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(9) Connect negati ve cabl e to battery.
(10) Start engi ne and check for l eaks.
Fig. 15 Removing Pull Tab
FUEL TUBE OR FUEL SYSTEM COMPONENT PULL TAB QUICK-CON- NECT FITTING FUEL TUBE STOP
Fig. 16 Typical Two-Tab Type Quick-ConnectFitting
FUEL RAIL QUICK-CONNECT FITTING
TABS
ZG FUEL SYSTEM 14 - 13
SERVICE PROCEDURES (Continued)
PLASTIC RETAINER RING TYPE FITTING
Thi s type of fi tti ng can be i denti fi ed by the use of a
ful l -round pl asti c retai ner ri ng (Fi g. 17) usual l y bl ack
i n col or.
CAUTION: The interior components (o-rings, spac-
ers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is nec-
essary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
DISCONNECTION/CONNECTION
(1) Di sconnect negati ve battery cabl e from the bat-
tery.
(2) Perform the fuel pressure rel ease procedure.
Refer to the Fuel Pressure Rel ease Procedure i n thi s
secti on.
(3) Cl ean the fi tti ng of any forei gn materi al before
di sassembl y.
(4) To rel ease the fuel system component from the
qui ck-connect fi tti ng, fi rml y push the fi tti ng towards
the component bei ng servi ced whi l e fi rml y pushi ng
the pl asti c retai ner ri ng i nto the fi tti ng (Fi g. 17).
Wi th the pl asti c ri ng depressed, pul l the fi tti ng from
the component. The plastic retainer ring must be
pressed squarely into the fitting body. If this
retainer is cocked during removal, it may be
difficult to disconnect fitting. Use an open-end
wrench on the shoulder of the plastic retainer
ring to aid in disconnection.
(5) After di sconnecti on, the pl asti c retai ner ri ng
wi l l remai n wi th the qui ck-connect fi tti ng connector
body.
(6) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage. Repl ace
as necessary.
(7) Pri or to connecti ng the qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean the parts wi th a l i nt-free
cl oth. Lubri cate them wi th cl ean engi ne oi l .
(8) I nsert the qui ck-connect fi tti ng i nto the compo-
nent bei ng servi ced unti l a cl i ck i s fel t.
(9) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(10) Connect negati ve battery cabl e to battery.
(11) Start engi ne and check for l eaks.
FUEL LINE AT FUEL RAIL
Use the following procedure if the fuel rail is
equipped with a fuel pressure test port.
A l atch cl i p i s used to secure the fuel l i ne to the
fuel rai l on certai n engi nes (Fi g. 18). A speci al tool
wi l l be necessary to separate the fuel l i ne from the
fuel rai l after the l atch cl i p i s removed.
DISCONNECTION/CONNECTION AT FUEL RAIL
(1) Di sconnect the negati ve battery cabl e from bat-
tery.
(2) Perform the fuel pressure rel ease procedure.
Refer to the Fuel Pressure Rel ease Procedure i n thi s
secti on.
(3) Cl ean the fi tti ng of any forei gn materi al before
di sassembl y.
Fig. 17 Plastic Retainer Ring Type Fitting
FUEL TUBE REMOVAL QUICK CONNECT FITTING INSTALLATION PUSH PLASTIC RETAINER PUSH PUSH PUSH PUSH
Fig. 18 Latch Clip LocationTypical
FUEL RAIL MOUNTING BOLTS FUEL RAIL CONNECT- ING HOSE LATCH CLIP FUEL RAIL ASSEMBLY
14 - 14 FUEL SYSTEM ZG
SERVICE PROCEDURES (Continued)
(4) Pry up on the l atch cl i p wi th a screwdri ver
(Fi g. 19).
(5) Sl i de the l atch cl i p toward the fuel rai l whi l e
l i fti ng wi th the screwdri ver.
(6) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055- 1 or equi val ent) i nto the fuel l i ne
(Fi g. 20). Use thi s tool to rel ease the l ocki ng fi ngers
i n the end of the l i ne.
(7) Wi th the speci al tool sti l l i nserted, pul l the
fuel l i ne from the fuel rai l .
(8) After di sconnecti on, the l ocki ng fi ngers wi l l
remai n wi thi n the qui ck-connect fi tti ng at the end of
the fuel l i ne.
(9) I nspect fuel l i ne fi tti ng, l ocki ng fi ngers and
fuel rai l fi tti ng for damage. Repl ace as necessary.
(10) Pri or to connecti ng the fuel l i ne to the fuel
rai l , check condi ti on of both fi tti ngs. Cl ean the parts
wi th a l i nt-free cl oth. Lubri cate them wi th cl ean
engi ne oi l .
(11) I nsert the fuel l i ne onto the fuel rai l unti l a
cl i ck i s fel t.
(12) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel l i ne and fi tti ng (15-30 l bs.).
(13) I nstal l l atch cl i p (snaps i nto posi ti on). If the
latch clip will not fit, this indicates the fuel line
is not properly installed to the fuel rail.
Recheck the fuel line connection.
(14) Connect negati ve battery cabl e to battery.
(15) Start engi ne and check for l eaks.
FUEL LINE AT FUEL RAIL5.2L ENGINES
Use the following procedure if the fuel rail is
not equipped with a fuel pressure test port.
A speci al l atch cl i p i s used to secure the fuel l i ne to
the fuel rai l on thi s parti cul ar engi ne (Fi g. 21).
DISCONNECTION/CONNECTION AT FUEL RAIL
(1) Di sconnect the negati ve battery cabl e from bat-
tery.
(2) Perform the fuel pressure rel ease procedure.
Refer to the Fuel Pressure Rel ease Procedure i n thi s
secti on.
(3) Cl ean the fi tti ng of any forei gn materi al before
di sassembl y.
(4) Compress the cl i p fi ngers (Fi g. 21) and pul l cl i p
strai ght up for removal .
(5) Pul l the fuel l i ne from the fuel rai l .
(6) After di sconnecti on, the l ocki ng fi ngers wi l l
remai n wi thi n the qui ck-connect fi tti ng i n the fuel
rai l .
(7) I nspect fuel l i ne fi tti ng, l ocki ng fi ngers and
fuel rai l fi tti ng for damage. Repl ace as necessary.
(8) Pri or to connecti ng the fuel l i ne to the fuel
rai l , check condi ti on of both fi tti ngs. Cl ean the parts
wi th a l i nt-free cl oth. Lubri cate them wi th cl ean
engi ne oi l .
(9) I nsert the fuel l i ne i nto the fuel rai l .
(10) I nstal l l atch cl i p wi th fi ngers down (snaps
i nto posi ti on). The fi ngers shoul d protrude bel ow the
Fig. 19 Latch Clip RemovalTypical
FUEL LINE SCREWDRIVER LATCH CLIP FUEL RAIL
Fig. 20 Fuel Line DisconnectionTypical
SPECIAL FUEL LINE TOOL FUEL LINE FUEL RAIL
Fig. 21 Latch Clip5.2L/5.9L EnginesWithout Fuel
Test Port
FUEL RAIL VEHICLE FUEL LINE CLIP FINGERS LATCH CLIP
ZG FUEL SYSTEM 14 - 15
SERVICE PROCEDURES (Continued)
fuel rai l i f properl y i nstal l ed (Fi g. 21). If the latch
clip will not fit, this indicates the fuel line is
not properly installed to the fuel rail. Recheck
the fuel line connection.
(11) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel l i ne and fi tti ng (15-30 l bs.).
(12) Connect negati ve battery cabl e to battery.
(13) Start engi ne and check for l eaks.
REMOVAL AND INSTALLATION
FUEL FILTER/FUEL PRESSURE REGULATOR
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s l ocated on the fuel pump modul e. The fuel
pump modul e i s l ocated on top of fuel tank.
The fi l ter/regul ator may be removed wi thout
removi ng fuel pump modul e al though fuel tank must
be removed.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Cl ean area around fi l ter/regul ator.
(3) Remove retai ner cl amp from top of fi l ter/regu-
l ator (Fi g. 22). Cl amp snaps to tabs on pump modul e.
Di scard ol d cl amp.
(4) Pry fi l ter/regul ator from top of pump modul e
wi th 2 screwdri vers. Uni t i s snapped i nto modul e.
(5) Di scard gasket bel ow fi l ter/regul ator (Fi g. 23).
(6) Before di scardi ng fi l ter/regul ator assembl y,
i nspect assembl y to veri fy that o-ri ngs (Fi g. 24) are
i ntact. I f the smal l est of the two o-ri ngs can not be
found on bottom of fi l ter/regul ator, i t may be neces-
sary to remove i t from the fuel i nl et passage i n fuel
pump modul e.
INSTALLATION
(1) Cl ean recessed area i n pump modul e where fi l -
ter/regul ator i s to be i nstal l ed.
(2) Obtai n new fi l ter/regul ator (two new o-ri ngs
shoul d al ready be i nstal l ed).
(3) Appl y a smal l amount of cl ean engi ne oi l to
o-ri ngs. Do not install o-rings separately into
fuel pump module. They will be damaged when
installing filter/regulator.
(4) I nstal l new gasket to top of fuel pump modul e.
(5) Press new fi l ter/regul ator i nto top of pump
modul e unti l i t snaps i nto posi ti on (a posi ti ve cl i ck
must be heard or fel t).
(6) The arrow (Fi g. 22) on top of fuel pump modul e
shoul d be poi nted towards front of vehi cl e (12 ocl ock
posi ti on).
Fig. 22 Fuel Filter/Fuel Pressure Regulator
RETAINER CLAMP
FUEL FILTER/FUEL PRES- SURE REGULATOR
Fig. 23 Fuel Filter/Fuel Pressure RegulatorGasket
TOP OF MODULE
GASKET
Fig. 24 Fuel Filter/Fuel Pressure RegulatorO-Rings
FUEL FILTER/FUEL PRES- SURE REGULATOR
TO FUEL INJECTORS
14 - 16 FUEL SYSTEM ZG
SERVICE PROCEDURES (Continued)
(7) Rotate fi l ter/regul ator unti l fuel suppl y tube
(fi tti ng) i s poi nted to 11 ocl ock posi ti on.
(8) I nstal l new retai ner cl amp (cl amp snaps over
top of fi l ter/regul ator and l ocks to fl anges on pump
modul e).
(9) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL PUMP MODULE
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Drai n fuel tank and remove tank. Refer to the
Fuel Tank Removal /I nstal l ati on secti on of thi s group.
(2) Thoroughl y wash and cl ean area around pump
modul e to prevent contami nants from enteri ng tank.
(3) The pl asti c fuel pump modul e l ocknut i s
threaded onto fuel tank (Fi g. 25). I nstal l Speci al Tool
6856 to fuel pump modul e l ocknut and remove l ock-
nut (Fi g. 26). The fuel pump modul e wi l l spri ng up
when l ocknut i s removed.
(4) Remove modul e from fuel tank.
INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the module gasket must be replaced.
(1) Usi ng a new gasket, posi ti on fuel pump modul e
i nto openi ng i n fuel tank.
(2) Posi ti on l ocknut over top of fuel pump modul e.
(3) Rotate modul e unti l arrow (Fi g. 22) i s poi nted
toward front of vehi cl e (12 ocl ock posi ti on). Thi s step
must be done to prevent fl oat/fl oat rod assembl y from
contacti ng si des of fuel tank.
(4) I nstal l Speci al Tool 6856 to l ocknut.
(5) Ti ghten l ocknut to 34 Nm (25 ft. l bs.) torque.
(6) Rotate fuel fi l ter/fuel pressure regul ator unti l
i ts fi tti ng i s poi nted to 11 ocl ock posi ti on.
(7) I nstal l fuel tank. Refer to Fuel Tank I nstal l a-
ti on i n thi s secti on.
FUEL PUMP INLET FILTER
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of fuel pump modul e (Fi g. 27). The fuel
pump modul e i s l ocated on top of fuel tank.
Fig. 25 Top View of Fuel Tank and Fuel
PumpModule
FRONT
ALIGNMENT ARROW (12 OCLOCK)
Fig. 26 Locknut Removal/InstallationTypical
SPECIAL TOOL 6856 LOCKNUT
Fig. 27 Fuel Pump Inlet Filter
FUEL PUMP MODULE
FUEL PUMP INLET FILTER
ZG FUEL SYSTEM 14 - 17
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove fi l ter by pryi ng from bottom of modul e
wi th 2 screwdri vers. Fi l ter i s snapped to modul e.
(4) Cl ean bottom of pump modul e.
INSTALLATION
(1) Snap new fi l ter to bottom of modul e.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL GAUGE SENDING UNIT
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 28). The fuel pump modul e i s l ocated on
top of fuel tank.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 29) to remove send-
i ng uni t from pump modul e.
INSTALLATION
(1) Posi ti on sendi ng uni t to pump modul e and
snap i nto pl ace.
(2) Connect el ectri cal connector to termi nal s.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(4) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL INJECTOR RAIL 5. 2L/5. 9L ENGINES
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE SERVICING THE FUEL
RAIL ASSEMBLY, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED.
To rel ease fuel pressure, refer to the Fuel System
Pressure Rel ease Procedure found i n thi s group.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate the rail
halves at the connecting hose (Fig. 30). Due to the
design of this connecting hose, it does use any
clamps. Never attempt to install a clamping device
of any kind to the hose. When removing the fuel rail
assembly for any reason, be careful not to bend or
kink the connecting hose.
REMOVAL
(1) Remove negati ve battery cabl e at battery.
(2) Remove ai r duct at throttl e body.
(3) Perform the fuel pressure rel ease procedure.
(4) Remove throttl e body from i ntake mani fol d.
Refer to Throttl e Body removal i n thi s group.
(5) I f equi pped wi th ai r condi ti oni ng, remove the
A-shaped A/C compressor-to-i ntake mani fol d support
bracket (three bol ts) (Fi g. 31).
(6) Di sconnect el ectri cal connectors at al l fuel
i njectors (Fi g. 32). The factory fuel i njecti on wi ri ng
harness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on.
(7) Di sconnect fuel tube (l i ne) at si de of fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures,
Fig. 28 Fuel Gauge Sending Unit Location
FUEL GAUGE FLOAT
PICK-UP FILTER
FUEL GAUGE SENDING UNIT
Fig. 29 Fuel Gauge Sending UnitRelease Tab
ELECTRICAL CONNECTOR
FUEL GAUGE SENDING UNIT
14 - 18 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
(8) Remove the remai ni ng fuel rai l mounti ng bol ts.
(9) Gentl y rock and pul l the left fuel rai l unti l the
fuel i njectors just start to cl ear the i ntake mani fol d.
Gentl y rock and pul l the right fuel rai l unti l the fuel
i njectors just start to cl ear the i ntake mani fol d.
Repeat thi s procedure (l eft/ri ght) unti l al l fuel i njec-
tors have cl eared the i ntake mani fol d.
(10) Remove fuel rai l (wi th i njectors attached)
from engi ne.
(11) Remove the cl i p(s) retai ni ng the i njector(s) to
fuel rai l (Fi g. 33) or (Fi g. 34).
INSTALLATION
(1) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(2) I nstal l i njector(s) and i njector cl i p(s) to fuel
rai l .
(3) Posi ti on the fuel rai l /fuel i njector assembl y to
the i njector openi ngs on the i ntake mani fol d.
(4) Gui de each i njector i nto the i ntake mani fol d.
Be careful not to tear the i njector o-ri ng.
(5) Push the right fuel rai l down unti l fuel i njec-
tors have bottomed on i njector shoul der. Push the
left fuel rai l down unti l fuel i njectors have bottomed
on i njector shoul der.
(6) I nstal l fuel rai l mounti ng bol ts.
(7) Connect el ectri cal connector to i ntake mani fol d
ai r temperature sensor.
(8) Connect wi ri ng to al l fuel i njectors. The i njec-
tor wi ri ng harness i s numeri cal l y tagged.
(9) I nstal l the A/C support bracket (i f equi pped).
(10) I nstal l throttl e body to i ntake mani fol d. Refer
to Throttl e Body i nstal l ati on i n thi s secti on of the
group.
(11) I nstal l fuel tube (l i ne) at si de of fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures.
Fig. 30 Fuel Rail AssemblyTypical
FUEL RAIL CONNECTING HOSE
FUEL RAIL
Fig. 31 A/C Compressor Support BracketTypical
AIR CONDITIONING COMPRESSOR SUPPORT BRACKET MOUNTING BOLTS
Fig. 32 Fuel Injector ConnectorsTypical
FUEL RAIL FUEL INJECTOR HAR- NESS CONNECTORS FUEL INJECTOR
Fig. 33 Fuel Injector MountingTypical
CLIP INJECTOR FUEL RAIL
ZG FUEL SYSTEM 14 - 19
REMOVAL AND INSTALLATION (Continued)
(12) I nstal l ai r duct to throttl e body.
(13) Connect battery cabl e to battery.
(14) Start engi ne and check for l eaks.
FUEL INJECTOR RAIL 4. 0L ENGINE
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. THIS PRESSURE MUST BE RELEASED
BEFORE SERVICING THE FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Di sconnect the negati ve battery cabl e from bat-
tery.
(3) Perform the Fuel System Pressure Rel ease Pro-
cedure as descri bed i n thi s Group.
(4) Remove and numeri cal l y attach a tag (i f fuel
i njector i s not al ready tagged), the i njector harness
connectors. Do thi s at each i njector (Fi g. 35).
(5) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Fuel Tubes/Li nes/Hoses and
Cl amps, or Qui ck-Connect Fi tti ngs. These can both
be found i n the Fuel Del i very secti on of thi s group.
(6) Remove fuel rai l mounti ng bol ts (Fi g. 35).
(7) Remove cabl e mounti ng bracket and cabl es at
i ntake mani fol d.
(8) Remove fuel rai l by gentl y rocki ng unti l al l the
fuel i njectors are out of the i ntake mani fol d.
INSTALLATION
(1) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(2) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n the i ntake mani fol d. Seat
i njectors i nto mani fol d.
(3) Ti ghten fuel rai l mounti ng bol ts to 27 Nm (20
ft. l bs.) torque.
(4) I nstal l cabl e mounti ng bracket and cabl es to
i ntake mani fol d.
(5) Connect i njector harness connectors to appro-
pri ate (tagged) i njector.
(6) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer to thi s group for procedures.
(7) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(8) I nstal l fuel tank cap.
(9) Connect negati ve battery cabl e to battery.
(10) Start engi ne and check for fuel l eaks.
FUEL INJECTOR(S)
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE EVEN WITH THE ENGINE
TURNED OFF. BEFORE SERVICING THE FUEL
INJECTOR(S), THE FUEL SYSTEM PRESSURE
MUST BE RELEASED.
To rel ease fuel pressure, refer to the Fuel System
Pressure Rel ease Procedure.
To remove one or more fuel i njectors, the fuel rai l
assembl y must be removed from engi ne.
REMOVAL
(1) Remove ai r duct at throttl e body.
(2) Remove fuel i njector rai l assembl y. Refer to
Fuel I njector Rai l removal i n thi s secti on.
(3) Remove the cl i p(s) retai ni ng the i njector(s) to
fuel rai l (Fi g. 33) or (Fi g. 34).
(4) Remove i njector(s) from fuel rai l .
Fig. 34 Injector Retaining ClipsTypicalInjector
PLIERS INJECTORCLIP FUEL INJEC- TOR FUEL RAIL
Fig. 35 Fuel Rail Mounting
FUEL PRESSURE TEST PORT (IF EQUIPPED) FUEL INJECTOR NUMBEREDTAG FUEL RAIL FUEL RAIL MOUNTING BOLTS
14 - 20 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(2) I nstal l i njector(s) and i njector cl i p(s) to fuel
rai l .
(3) I nstal l fuel rai l assembl y. Refer to Fuel I njector
Rai l i nstal l ati on.
(4) I nstal l ai r duct at throttl e body.
(5) Start engi ne and check for l eaks.
FUEL TANK
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. THIS PRESSURE MUST BE RELEASED
BEFORE SERVICING FUEL TANK.
The el ectri c fuel pump may be acti vated al l owi ng
fuel tank to be drai ned. Thi s i s done at fuel rai l con-
necti on usi ng DRB scan tool . Refer to scan tool for
fuel pump acti vati on procedures. Before di sconnect-
i ng fuel l i ne at fuel rai l , rel ease fuel pressure. Refer
to the Fuel System Pressure Rel ease Procedure i n
thi s group for procedures. Attach end of speci al test
hose tool number 6541, 6539, 6631 or 6923 at fuel
rai l di sconnecti on (tool number wi l l depend on model
and/or engi ne appl i cati on). Posi ti on opposi te end of
thi s hose tool to an approved gasol i ne drai ni ng sta-
ti on. Acti vate fuel pump and drai n tank unti l empty.
I f el ectri c fuel pump i s not operati ng, tank wi l l have
to be l owered for fuel drai ni ng. Refer to fol l owi ng
procedures.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Rel ease fuel system pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group.
(3) Rai se and support vehi cl e.
(4) Remove fuel tank fi l l hose and vent hose
cl amps at fuel tank fi l l er tube (Fi g. 36). Remove both
hoses at fuel fi l l er tube (Fi g. 36).
(5) Remove rear tow hooks (i f equi pped).
(6) Remove fuel tank ski d pl ate mounti ng nuts/
bol ts and remove ski d pl ate (Fi g. 37) (i f equi pped).
(7) Remove opti onal trai l er hi tch (i f equi pped).
(8) Remove exhaust tai l pi pe heat shi el d mounti ng
bol ts and remove shi el d.
CAUTION: To protect fuel tank from exhaust heat,
this shield must reinstalled after tank installation.
(9) Pl ace a hydraul i c jack to bottom of fuel tank.
WARNING: PLACE A SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
(10) Di sconnect fuel suppl y l i ne near front of fuel
tank (Fi g. 38). Refer to Fuel Tubes/Li nes/Hoses and
Cl amps i n thi s group. Al so refer to Qui ck-Connect
Fi tti ngs for procedures.
(11) Di sconnect EVAP cani ster vent l i ne near
front of tank (Fi g. 38).
Fig. 36 Fuel Filler Tube and Hoses
FUEL FILLER HOSE HOSE CLAMPS FUEL TANK FILLER TUBE CAP FUEL TANK FILLER TUBE FUEL VENT HOSE
Fig. 37 Fuel Tank Mounting
ACCESS HOLE HOSE CLAMPS FUEL FILLER HOSES FUEL TANK MOUNTING BOLTS (2) FUEL TANK NUTS (2) STRAP OPTIONAL FUEL TANK SKID PLATE SKID PLATE MOUNTING NUTS/BOLTS (9) FUEL TANK STRAPS (2)
ZG FUEL SYSTEM 14 - 21
REMOVAL AND INSTALLATION (Continued)
(12) Di sconnect fuel pump modul e el ectri cal con-
nector (pi gtai l harness) near front of tank (Fi g. 38).
Harness connector i s cl i pped to body.
(13) Remove two fuel tank strap nuts (Fi g. 37).
Posi ti on both tank support straps away from tank.
(14) Careful l y l ower ri ght si de of tank whi l e feed-
i ng both fuel hoses through access hol e i n body. Fuel
Tank Full And Not Drained Using DRB Scan
Tool: To prevent fuel l oss through hoses, keep l eft
si de of tank hi gher than ri ght si de whi l e l oweri ng.
Do not al l ow hose openi ngs to drop l ower than top of
tank.
(15) Conti nue l oweri ng tank unti l cl ear of vehi cl e.
Pl ace tank on fl oor wi th l eft si de (hose si de) hi gher
than ri ght si de.
(16) Drai n tank by removi ng fuel fi l l hose at tank.
Fuel fi l l hose i s l argest of 2 hoses (Fi g. 39). I nsert the
drai n hose (from an approved gasol i ne drai ni ng sta-
ti on) i nto hose openi ng. Drai n tank unti l empty.
(17) I f fuel pump modul e removal i s necessary,
refer to Fuel Pump Modul e Removal /I nstal l ati on i n
thi s group for procedures.
INSTALLATION
(1) I f fuel pump modul e i s bei ng i nstal l ed, refer to
Fuel Pump Modul e Removal /I nstal l ati on i n thi s
group for procedures.
(2) I nstal l fuel fi l l /vent hoses to tank fi tti ngs. To
prevent hose from ki nki ng, rotate each hose unti l
i ndex mark on hose i s al i gned to i ndex tang on fuel
tank (Fi g. 39).
(3) I nstal l hose cl amps to hoses. Posi ti on cl amps
between i ndex marks on each hose (Fi g. 39).
(4) Posi ti on fuel tank to hydraul i c jack.
(5) Rai se tank i nto posi ti on whi l e gui di ng fuel fi l l
and vent hoses i nto and through access hol e i n body.
(6) Conti nue rai si ng tank unti l posi ti oned to body.
(7) Attach two fuel tank mounti ng straps and
mounti ng nuts.
CAUTION: The two mounting nuts must be tight-
ened until 8386 mm (3.27 in.3.39 in.) is attained
between end of mounting bolt and bottom of strap.
See insert (Fig. 37). Do not over tighten nuts.
(8) I nstal l both fuel hoses to fuel fi l l tube. Ti ghten
both retai ni ng cl amps.
(9) Connect fuel pump modul e pi gtai l harness el ec-
tri cal connector near front of tank.
(10) Connect fuel pump modul e suppl y l i ne near
front of tank. Refer to Fuel Tubes/Li nes/Hoses and
Cl amps i n thi s group. Al so refer to Qui ck-Connect
Fi tti ngs for procedures.
(11) Connect EVAP hose near front of tank.
(12) I nstal l exhaust tai l pi pe heat shi el d.
(13) I nstal l fuel tank ski d pl ate and trai l er hi tch
(i f equi pped).
(14) I nstal l rear tow hooks (i f equi pped).
(15) Lower vehi cl e and connect battery cabl e to
battery.
FUEL TANK FILLER TUBE CAP
I f repl acement of the fuel tank fi l l er tube cap i s
necessary, i t must be repl aced wi th an i denti cal cap
to be sure of correct system operati on.
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
Fig. 38 Fuel Tank Connections at Front ofFuel Tank
FUEL SUPPLY LINE CON- NECTION
FUEL PUMP MODULE CON- NECTOR
Fig. 39 Fuel Fill/Vent Hose Index Marks
FUEL TANK
CLAMP INDEX MARKS
TANK INDEX TANGS
14 - 22 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
ACCELERATOR PEDAL
The accel erator pedal i s connected to the throttl e
body l i nkage by the throttl e cabl e. The cabl e i s pro-
tected by a pl asti c sheathi ng and i s connected to the
throttl e body l i nkage by a bal l socket. I t i s connected
to the accel erator pedal arm by a pl asti c retai ner
(cl i p) (Fi g. 40). Thi s retai ner (cl i p) snaps i nto the top
of the accel erator pedal arm. Retai ner tabs (bui l t i nto
the cabl e sheathi ng) fasten the cabl e to the dash
panel .
Dual throttl e return spri ngs (attached to the throt-
tl e shaft) are used to cl ose the throttl e.
CAUTION: Never attempt to remove or alter these
springs.
REMOVAL
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner (cl i p) and throt-
tl e cabl e core wi re from upper end of pedal arm.
Pl asti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(2) Remove accel erator pedal bracket nuts. Remove
accel erator pedal assembl y.
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
8.5 Nm (75 i n. l bs.) torque.
(2) Sl i de throttl e cabl e i nto openi ng i n top of pedal
arm. Push pl asti c cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i nto pl ace.
(3) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
THROTTLE CABLE
REMOVAL
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner (cl i p) and throt-
tl e cabl e core wi re from upper end of pedal arm (Fi g.
40). Pl asti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(2) Remove the cabl e core wi re at pedal arm.
(3) From i nsi de the vehi cl e, pi nch both si des of the
cabl e housi ng retai ner tabs (Fi g. 40). at the dash
panel . Remove cabl e housi ng from dash panel and
pul l i nto the engi ne compartment.
(4) 4.0L Engi ne: Remove cabl e from cl i p on engi ne
val ve cover (Fi g. 41).
(5) Remove the throttl e cabl e bal l end socket at
throttl e body l i nkage (Fi g. 42) or (Fi g. 43) (snaps off).
(6) 4.0L Engi ne: Remove throttl e cabl e from throt-
tl e body mounti ng bracket by compressi ng retai ner
tabs and pushi ng cabl e through hol e i n bracket.
Remove throttl e cabl e from vehi cl e.
(7) 5.2L/5.9L Engi nes: Remove cabl e housi ng at
throttl e body mounti ng bracket by pressi ng forward
on rel ease tab wi th a smal l screwdri ver (Fi g. 44). To
Fig. 40 Accelerator Pedal Mounting
RETAINER TABS CABLE CLIP BRACKET NUTS (2) PEDAL/BRACKET ASSEMBLY
Fig. 41 Throttle Cable Routing4.0LEngine
TRANSMISSION KICKDOWN CABLE ACCELERATOR PEDAL CABLE
ZG FUEL SYSTEM 14 - 23
REMOVAL AND INSTALLATION (Continued)
prevent cable housing breakage, press on the
tab only enough to release the cable from the
bracket. Li ft the cabl e housi ng strai ght up from
bracket whi l e pressi ng on rel ease tab. Remove throt-
tl e cabl e from vehi cl e.
INSTALLATION
(1) 4.0L Engi ne: Sl i de throttl e cabl e through hol e
i n throttl e body bracket unti l retai ner tabs l ock i nto
bracket. Connect cabl e bal l end to throttl e body l i nk-
age bal l (snaps on).
(2) 5.2L/5.9L Engi nes: Connect cabl e bal l end to
throttl e body l i nkage bal l (snaps on). Connect cabl e
to throttl e body bracket (push down and l ock).
(3) 4.0L Engi ne: Snap cabl e i nto cl i p on engi ne
val ve cover.
(4) Push other end of cabl e through openi ng i n
dash panel unti l retai ni ng tabs l ock i nto panel .
(5) From i nsi de dri vers compartment, sl i de throttl e
cabl e core wi re i nto openi ng i n top of pedal arm.
Push cabl e retai ner (cl i p) i nto pedal arm openi ng
unti l i t snaps i n pl ace.
(6) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
SPECIFICATIONS
VECI LABEL
I f anythi ng di ffers between the speci fi cati ons found
on the Vehi cl e Emi ssi on Control I nformati on (VECI )
l abel and the fol l owi ng speci fi cati ons, use speci fi ca-
ti ons on VECI l abel . The VECI l abel i s l ocated i n the
engi ne compartment.
FUEL TANK CAPACITY
FUEL SYSTEM PRESSURE
339 kPa 34 kPa (49.2 psi 5 psi ).
Fig. 42 Throttle Cable at Throttle Body4.0LEngine
OFF
THROTTLE CABLE
Fig. 43 Throttle Cable at Throttle Body5.2L/5.9LV-8
Engines
THROTTLE LEVER PIN
CAM (V-8 ENGINE ONLY)
THROTTLE CABLE END
Fig. 44 Cable Release Tab5.2L/5.9LEngines
Typical
PUSH ON TAB FOR REMOVAL TAB
Models Liters U.S. Gallons
All 87 23
Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
14 - 24 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
TORQUE CHART
DESCRIPTION TORQUE
Accel erator Pedal Bracket
Mounti ng Nuts . . . . . . . . . . . 8.5 Nm (75 i n. l bs.)
Fuel Pump Modul e Locknut . . . . 34 Nm (25 ft. l bs.)
Fuel Rai l Mounti ng Bol ts
4.0L Engi ne . . . . . . . . . . . . . 11 Nm (100 i n. l bs.)
Fuel Rai l Mounti ng Bol ts
5.2L/5.9L Engi nes . . . . . . . . 23 Nm (200 i n. l bs.)
Fuel Tank Mounti ng Nuts . . . Refer To Manual Text
Fuel Hose Cl amps . . . . . . . . . . . . 1 Nm (15 i n. l bs.)
ZG FUEL SYSTEM 14 - 25
SPECIFICATIONS (Continued)
FUEL INJ ECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 27
MODES OF OPERATION . . . . . . . . . . . . . . . . . 27
DESCRIPTION AND OPERATION
OXYGEN SENSOR (O2S)PCM INPUT . . . . . . 34
AIR CONDITIONING (A/C) CLUTCH RELAY
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . 37
AIR CONDITIONING (A/C) CONTROLSPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
AUTO SHUTDOWN (ASD) RELAYPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
AUTOMATIC SHUTDOWN (ASD) RELAY
SENSEPCM INPUT . . . . . . . . . . . . . . . . . . 31
BATTERY TEMPERATURE SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BATTERY VOLTAGEPCM INPUT . . . . . . . . . . 31
BRAKE SWITCHPCM INPUT . . . . . . . . . . . . . 32
CAMSHAFT POSITION SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 32
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . . . 38
CRANKSHAFT POSITION SENSOR4.0L
ENGINEPCM INPUT . . . . . . . . . . . . . . . . . 32
CRANKSHAFT POSITION SENSOR5.2L/5.9L
ENGINESPCM INPUT . . . . . . . . . . . . . . . . 32
DATA LINK CONNECTORPCM INPUT AND
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DUTY CYCLE EVAP PURGE SOLENOID
VALVE-PCM OUTPUT . . . . . . . . . . . . . . . . . . 38
ENGINE COOLANT TEMPERATURE SENSOR
4.0L ENGINEPCM INPUT . . . . . . . . . . . . . . 33
ENGINE COOLANT TEMPERATURE SENSOR
5.2L/5.9L ENGINESPCM INPUT . . . . . . . . . 33
FIVE VOLT SENSOR SUPPLYPRIMARY . . . . 32
FIVE VOLT SENSOR SUPPLYSECONDARY . 32
FUEL INJECTORS4.0L ENGINEPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FUEL INJECTORS5.2L/5.9L ENGINESPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FUEL LEVEL SENSORPCM INPUT . . . . . . . . 32
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . . . 39
GENERATOR FIELD DRIVER (-)
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . 39
GENERATOR FIELD SOURCE (+)PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
GENERATOR LAMPPCM OUTPUT . . . . . . . . 39
GENERATOR OUTPUTPCM INPUT . . . . . . . 34
GOVERNOR PRESSURE SOLENOIDPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
IDLE AIR CONTROL (IAC) MOTOR4.0L
ENGINEPCM OUTPUT . . . . . . . . . . . . . . . . 40
IDLE AIR CONTROL (IAC) MOTOR5.2L/5.9L
ENGINESPCM OUTPUT . . . . . . . . . . . . . . 39
IGNITION CIRCUIT SENSEPCM INPUT . . . . 34
IGNITION COIL4.0L ENGINES
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . 40
IGNITION COIL5.2L/5.9L ENGINESPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR4.0L ENGINEPCM INPUT . . . . . 34
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR5.2L/5.9L ENGINES
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 34
LEAK DETECTION PUMP (SWITCH) SENSE
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 35
LEAK DETECTION PUMPPCM OUTPUT . . . . 40
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPPCM OUTPUT . . . . . . . . . . . . . . . . . 41
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR4.0L ENGINEPCM INPUT . . . . . 35
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR5.2L/5.9L ENGINES
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 35
OIL PRESSURE SENSORPCM INPUT . . . . . 35
OUTPUT SHAFT SPEED SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 35
OVERDRIVE LAMPPCM OUTPUT . . . . . . . . . 41
OVERDRIVE/OVERRIDE SWITCH-PCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . 37
POWERTRAIN CONTROL MODULE (PCM) . . . 30
SENSOR RETURNPCM INPUT . . . . . . . . . . . 36
SIGNAL GROUNDPCM INPUT . . . . . . . . . . . 36
SPEED CONTROL SOLENOIDS
CM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPEED CONTROL SWITCHESPCM INPUT . . 36
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 30
TACHOMETERPCM OUTPUT . . . . . . . . . . . . 41
THREE-FOUR SHIFT SOLENOIDPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
THROTTLE BODY4.0L ENGINE . . . . . . . . . . 42
THROTTLE BODY5.2L/5.9L ENGINES . . . . . . 41
THROTTLE POSITION SENSOR (TPS)4.0L
ENGINEPCM INPUT . . . . . . . . . . . . . . . . . 36
THROTTLE POSITION SENSOR (TPS)5.2L/
5.9L ENGINESPCM INPUT . . . . . . . . . . . . . 36
TORQUE CONVERTOR CLUTCH (TCC)
SOLENOIDPCM OUTPUT . . . . . . . . . . . . . 41
14 - 26 FUEL SYSTEM ZG
TRANSMISSION GOVERNOR PRESSURE
SENSORPCM INPUT . . . . . . . . . . . . . . . . . 36
TRANSMISSION PARK/NEUTRAL SWITCH
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 36
TRANSMISSION RELAYPCM OUTPUT . . . . . 41
TRANSMISSION TEMPERATURE SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 36
VEHICLE SPEED AND DISTANCE SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING
ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . 49
CAMSHAFT AND CRANKSHAFT POSITION
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ENGINE COOLANT TEMPERATURE SENSOR
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 52
ENGINE COOLANT TEMPERATURE SENSOR
5.2L/5.9L ENGINES . . . . . . . . . . . . . . . . . . . . 52
IDLE AIR CONTROL (IAC) MOTOR4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
IDLE AIR CONTROL (IAC) MOTOR5.2L/5.9L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . 53
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR5.2L/5.9L ENGINE . . . . . . . . . . . . 53
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR TEST4.0L ENGINE . . . . . . . . . . . 50
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR TEST5.2L.5.9L ENGINES . . . . . . 49
OXYGEN (O2S) SENSORS4.0L ENGINE . . . . 52
OXYGEN (O2S) SENSORS5.2L/5.9L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 54
THROTTLE POSITION SENSOR (TPS)4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
THROTTLE POSITION SENSOR (TPS)5.2L/
5.9L ENGINES . . . . . . . . . . . . . . . . . . . . . . . 54
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . 54
VISUAL INSPECTION4.0L ENGINE . . . . . . . . 46
VISUAL INSPECTION5.2L/5.9L ENGINES . . . 42
REMOVAL AND INSTALLATION
AIR CLEANER ELEMENT (FILTER) . . . . . . . . . 63
AIR CLEANER HOUSING . . . . . . . . . . . . . . . . . 62
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 55
CAMSHAFT POSITION SENSOR . . . . . . . . . . . 61
CRANKSHAFT POSITION SENSOR . . . . . . . . . 61
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 60
ENGINE COOLANT TEMPERATURE SENSOR
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 64
ENGINE COOLANT TEMPERATURE SENSOR
5.2L/5.9L ENGINES . . . . . . . . . . . . . . . . . . . . 64
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . 56
IDLE AIR CONTROL (IAC) MOTOR4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
IDLE AIR CONTROL (IAC) MOTOR5.2L/5.9L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . 65
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR5.2L/5.9L ENGINES . . . . . . . . . . . 64
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . 60
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR5.2L/5.9L ENGINES . . . . . . . . . . . 59
OXYGEN SENSOR4.0L ENGINE . . . . . . . . . . 62
OXYGEN SENSOR5.2L/5.9L ENGINES . . . . . 61
POWERTRAIN CONTROL MODULE (PCM) . . . 60
THROTTLE BODY4.0L ENGINE . . . . . . . . . . 57
THROTTLE BODY5.2L/5.9L ENGINES . . . . . . 56
THROTTLE POSITION SENSOR (TPS)4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
THROTTLE POSITION SENSOR (TPS)5.2L/
5.9L ENGINES . . . . . . . . . . . . . . . . . . . . . . . 57
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . 65
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 66
VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SPECIAL TOOLS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 67
GENERAL INFORMATION
INTRODUCTION
Al l engi nes are equi pped wi th sequenti al Mul ti -
Port Fuel I njecti on (MFI ). The MFI system provi des
preci se ai r/fuel rati os for al l dri vi ng condi ti ons.
The powertrai n control modul e (PCM) (Fi g. 1) oper-
ates the fuel system.
MODES OF OPERATION
As i nput si gnal s to the powertrai n control modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop .
Duri ng Open Loop modes, the powertrai n control
modul e (PCM) recei ves i nput si gnal s and responds
onl y accordi ng to preset PCM programmi ng. I nput
from the oxygen (O2S) sensors i s not moni tored dur-
i ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
ZG FUEL SYSTEM 14 - 27
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
I gni ti on swi tch ON
Engi ne start-up (crank)
Engi ne warm-up
I dl e
Crui se
Accel erati on
Decel erati on
Wi de open throttl e (WOT)
I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
The powertrai n control modul e (PCM) pre-posi -
ti ons the i dl e ai r control (I AC) motor.
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
Throttl e posi ti on sensor (TPS) i s moni tored.
The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
The O2S sensor heater el ement i s energi zed vi a
the ASD rel ay. The O2S sensor i nput i s not used by
the PCM to cal i brate ai r-fuel rati o duri ng thi s mode
of operati on.
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The powertrai n control modul e (PCM) recei ves
i nputs from:
Battery vol tage
Engi ne cool ant temperature sensor
Crankshaft posi ti on sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Starter motor rel ay
Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the powertrai n control modul e (PCM) recei ves
i nputs from:
Battery vol tage
Crankshaft posi ti on sensor
Engi ne cool ant temperature sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
Fig. 1 Powertrain Control Module (PCM)
PCM (3) 32WAY CONNECTORS
14 - 28 FUEL SYSTEM ZG
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
The PCM operates the A/C compressor cl utch
through the cl utch rel ay. Thi s i s done i f A/C has been
sel ected by the vehi cl e operator and requested by the
A/C thermostat.
When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the powertrai n
control modul e (PCM) recei ves i nputs from:
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Battery vol tage
Crankshaft posi ti on sensor
Engi ne cool ant temperature sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Battery vol tage
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Oxygen sensors
Based on these i nputs, the fol l owi ng occurs:
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
The PCM operates the A/C compressor cl utch
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
CRUISE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At crui si ng speed, the power-
trai n control modul e (PCM) recei ves i nputs from:
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Battery vol tage
Engi ne cool ant temperature sensor
Crankshaft posi ti on sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
The PCM operates the A/C compressor cl utch
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
ACCELERATION MODE
Thi s i s an Open Loop mode. The powertrai n control
modul e (PCM) recogni zes an abrupt i ncrease i n
throttl e posi ti on or MAP pressure as a demand for
i ncreased engi ne output and vehi cl e accel erati on. The
PCM i ncreases i njector pul se wi dth i n response to
i ncreased throttl e openi ng.
DECELERATION MODE
When the engi ne i s at operati ng temperature, thi s
i s an Open Loop mode. Duri ng hard decel erati on, the
powertrai n control modul e (PCM) recei ves the fol l ow-
i ng i nputs.
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Battery vol tage
Engi ne cool ant temperature sensor
Crankshaft posi ti on sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Vehi cl e speed sensor
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
ZG FUEL SYSTEM 14 - 29
GENERAL INFORMATION (Continued)
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the powertrai n control modul e
(PCM) recei ves the fol l owi ng i nputs.
Battery vol tage
Crankshaft posi ti on sensor
Engi ne cool ant temperature sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
DESCRIPTION AND OPERATION
SYSTEM DIAGNOSIS
The Powertrai n Control Modul e (PCM) can test
many of i ts own i nput and output ci rcui ts. I f the
PCM senses a faul t i n a major system, i t stores a
Di agnosti c Troubl e Code (DTC) i n i ts memory.
Techni ci ans can di spl ay stored DTCs wi th di fferent
methods. One way i s usi ng the DRB scan tool .
Another way i s usi ng the mal functi on i ndi cator
(check engi ne) l amp. On certai n model s the vehi cl e
odometer can be used to di spl ay the numeri c DTC.
For DTC i nformati on, refer to Group 25, Emi ssi on
Control Systems. See On-Board Di agnosti cs.
POWERTRAIN CONTROL MODULE (PCM)
The powertrai n control modul e (PCM) (Fi g. 1) oper-
ates the fuel system. The PCM was formerl y referred
to as the SBEC or engi ne control l er. The PCM i s a
pre-programmed, tri ppl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, certai n
transmi ssi on features, speed control , ai r condi ti oni ng
compressor cl utch engagement and i dl e speed. The
PCM can adapt i ts programmi ng to meet changi ng
operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as Powertrai n Control Modul e
(PCM) Outputs. The sensors and swi tches that pro-
vi de i nputs to the PCM are consi dered Powertrai n
Control Modul e (PCM) I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed and the
brake swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: PCM Inputs:
A/C request (i f equi pped wi th factory A/C)
A/C sel ect (i f equi pped wi th factory A/C)
Auto shutdown (ASD) sense
Battery temperature
Battery vol tage
Brake swi tch
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
Camshaft posi ti on sensor si gnal
Crankshaft posi ti on sensor
Data l i nk connecti on for DRB scan tool
Engi ne cool ant temperature sensor
Fuel l evel
Generator (battery vol tage) output
I gni ti on ci rcui t sense (i gni ti on swi tch i n on/off/
crank/run posi ti on)
I ntake mani fol d ai r temperature sensor
Leak detecti on pump (swi tch) sense (i f equi pped)
Mani fol d absol ute pressure (MAP) sensor
Oi l pressure
14 - 30 FUEL SYSTEM ZG
GENERAL INFORMATION (Continued)
Output shaft speed sensor
Overdri ve/overri de swi tch
Oxygen sensors
Park/neutral swi tch (auto. trans. onl y)
Power ground
Sensor return
Si gnal ground
Speed control mul ti pl exed si ngl e wi re i nput
Throttl e posi ti on sensor
Transmi ssi on governor pressure sensor
Transmi ssi on temperature sensor
Vehi cl e speed sensor
NOTE: PCM Outputs:
A/C cl utch rel ay
Auto shutdown (ASD) rel ay
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
Data l i nk connecti on for DRB scan tool
EGR val ve control sol enoi d (i f equi pped)
EVAP cani ster purge sol enoi d
Fi ve vol t sensor suppl y (pri mary)
Fi ve vol t sensor suppl y (secondary)
Fuel i njectors
Fuel pump rel ay
Generator fi el d dri ver (-)
Generator fi el d dri ver (+)
Generator l amp (i f equi pped)
I dl e ai r control (I AC) motor
I gni ti on coi l
Leak detecti on pump
Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through CCD ci rcui ts.
Overdri ve i ndi cator l amp (i f equi pped)
Speed control vacuum sol enoi d
Speed control vent sol enoi d
Tachometer (i f equi pped). Dri ven through CCD
ci rcui ts.
Transmi ssi on convertor cl utch ci rcui t
Transmi ssi on 34 shi ft sol enoi d
Transmi ssi on rel ay
Transmi ssi on temperature l amp (i f equi pped)
Transmi ssi on vari abl e force sol enoi d
The powertrai n control modul e (PCM) contai ns a
vol tage convertor. Thi s converts battery vol tage to a
regul ated 5.0 vol ts. I t i s used to power the crankshaft
posi ti on sensor, camshaft posi ti on sensor and vehi cl e
speed sensor. The PCM al so provi des a fi ve (5) vol t
suppl y for the mani fol d absol ute pressure (MAP) sen-
sor and throttl e posi ti on sensor (TPS).
AIR CONDITIONING (A/C) CONTROLS PCM INPUT
The A/C control system i nformati on appl i es to fac-
tory i nstal l ed ai r condi ti oni ng uni ts.
A/C SELECT SIGNAL: When the A/C swi tch i s i n
the ON posi ti on, an i nput si gnal i s sent to the pow-
ertrai n control modul e (PCM). The si gnal i nforms the
PCM that the A/C has been sel ected. The PCM
adjusts i dl e speed to a pre-programmed rpm through
the i dl e ai r control (I AC) motor to compensate for
i ncreased engi ne l oad.
A/C REQUEST SIGNAL: Once A/C has been
sel ected, the powertrai n control modul e (PCM)
recei ves the A/C request si gnal from the cl utch
cycl i ng pressure swi tch. The i nput i ndi cates that the
evaporator pressure i s i n the proper range for A/C
appl i cati on. The PCM uses thi s i nput to cycl e the A/C
compressor cl utch (through the A/C rel ay). I t wi l l
al so determi ne the correct engi ne i dl e speed through
the i dl e ai r control (I AC) motor posi ti on.
I f the A/C l ow-pressure swi tch or hi gh-pressure
swi tch opens (i ndi cati ng a l ow or hi gh refri gerant
pressure), the PCM wi l l not recei ve an A/C request
si gnal . The PCM wi l l then remove the ground from
the A/C rel ay. Thi s wi l l deacti vate the A/C compres-
sor cl utch.
I f the swi tch opens, (i ndi cati ng that evaporator i s
not i n proper pressure range), the PCM wi l l not
recei ve the A/C request si gnal . The PCM wi l l then
remove the ground from the A/C rel ay, deacti vati ng
the A/C compressor cl utch.
AUTOMATIC SHUTDOWN (ASD) RELAY SENSE
PCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC). The
PDC i s l ocated i n the engi ne compartment (Fi g. 2).
Refer to l abel on PDC cover for rel ay l ocati on. The
rel ay i s used to connect the oxygen sensor heater el e-
ment, i gni ti on coi l and fuel i njectors to 12 vol t +
power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the powertrai n control modul e (PCM)
does not see 12 vol ts at thi s i nput when the ASD
shoul d be acti vated, i t wi l l set a di agnosti c troubl e
code (DTC).
BATTERY TEMPERATURE SENSOR PCM INPUT
Provi des a si gnal to the PCM correspondi ng to the
battery temperature. Refer to Group 8C, Chargi ng
System for addi ti onal i nformati on.
BATTERY VOLTAGE PCM INPUT
The battery vol tage i nput provi des power to the
Powertrai n Control Modul e (PCM). I t al so i nforms
the PCM what vol tage l evel i s suppl i ed to the i gni -
ti on coi l and fuel i njectors.
I f battery vol tage i s l ow, the PCM wi l l i ncrease
i njector pul se wi dth (peri od of ti me that the i njector
i s energi zed). Thi s i s done to compensate for the
ZG FUEL SYSTEM 14 - 31
DESCRIPTION AND OPERATION (Continued)
reduced fl ow through i njector caused by the l owered
vol tage.
BRAKE SWITCH PCM INPUT
When the brake l i ght swi tch i s acti vated, the Pow-
ertrai n Control Modul e (PCM) recei ves an i nput i ndi -
cati ng that the brakes are bei ng appl i ed. After
recei vi ng thi s i nput, the PCM mai ntai ns i dl e speed to
a schedul ed rpm through control of the I dl e Ai r Con-
trol (I AC) motor. The brake swi tch i nput i s al so used
to suppl y/deny power to the speed control servo sol e-
noi ds.
FIVE VOLT SENSOR SUPPLY PRIMARY
Suppl i es the requi red 5 vol t power source to the
crankshaft posi ti on sensor, camshaft posi ti on sensor,
MAP sensor and throttl e posi ti on sensor.
FIVE VOLT SENSOR SUPPLY SECONDARY
Suppl i es the requi red 5 vol t power source to the
transmi ssi on pressure sensor and the vehi cl e speed
sensor.
FUEL LEVEL SENSOR PCM INPUT
The fuel l evel sensor (fuel gauge sendi ng uni t)
sends a si gnal to the PCM to i ndi cate fuel l evel . The
purpose of thi s feature i s to prevent a fal se setti ng of
mi sfi re and fuel system moni tor troubl e codes i f the
fuel l evel i s l ess than approxi matel y 15 percent, or
more than approxi matel y 85 percent of i ts rated
capaci ty. I t i s al so used to send a si gnal for fuel
gauge operati on vi a the CCD bus ci rcui ts.
CAMSHAFT POSITION SENSOR PCM INPUT
A sync si gnal i s provi de by the camshaft posi ti on
sensor. The sensor l ocated i n the di stri butor on al l
4.0L/5.2L/5.9L engi nes (Fi g. 3). The sync si gnal from
thi s sensor works i n conjuncti on wi th the crankshaft
posi ti on sensor to provi de the powertrai n control
modul e (PCM) wi th i nputs. Thi s i s done to establ i sh
and mai ntai n correct i njector fi ri ng order.
Refer to Camshaft Posi ti on Sensor i n Group 8D,
I gni ti on System for more i nformati on.
CRANKSHAFT POSITION SENSOR 5. 2L/5. 9L
ENGINES PCM INPUT
Thi s sensor i s a hal l effect devi ce that detects
notches i n the fl ywheel (manual transmi ssi on) or
fl expl ate (automati c transmi ssi on).
Thi s sensor i s used to i ndi cate to the powertrai n
control modul e (PCM) that a spark and or fuel i njec-
ti on event i s to be requi red. The output from thi s
sensor, i n conjuncti on wi th the camshaft posi ti on sen-
sor si gnal , i s used to di fferenti ate between fuel i njec-
ti on and spark events. I t i s al so used to synchroni ze
the fuel i njectors wi th thei r respecti ve cyl i nders.
The sensor i s bol ted to the cyl i nder bl ock near the
rear of the ri ght cyl i nder head (Fi g. 4).
Refer to Group 8D, I gni ti on System for more
crankshaft posi ti on sensor i nformati on.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
CRANKSHAFT POSITION SENSOR 4. 0L
ENGINE PCM INPUT
Thi s sensor i s a hal l effect devi ce that detects
notches i n the fl ywheel (manual transmi ssi on) or
fl expl ate (automati c transmi ssi on).
Thi s sensor i s used to i ndi cate to the powertrai n
control modul e (PCM) that a spark and or fuel i njec-
Fig. 2 Power Distribution Center (PDC)
POWER DISTRIBUTION CEN- TER
Fig. 3 Camshaft Position SensorTypical(5.2L/5.9L
Distributor Shown)
SYNC SIGNAL GENERATOR CAMSHAFT POSITION SEN- SOR PULSE RING DISTRIBUTOR ASSEMBLY
14 - 32 FUEL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
ti on event i s to be requi red. The output from thi s
sensor, i n conjuncti on wi th the camshaft posi ti on sen-
sor si gnal , i s used to di fferenti ate between fuel i njec-
ti on and spark events. I t i s al so used to synchroni ze
the fuel i njectors wi th thei r respecti ve cyl i nders.
The sensor i s bol ted to the transmi ssi on bel l hous-
i ng (Fi g. 5).
Refer to Group 8D, I gni ti on System for more
crankshaft posi ti on sensor i nformati on.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
ENGINE COOLANT TEMPERATURE SENSOR 5. 2L/
5. 9L ENGINES PCM INPUT
The engi ne cool ant temperature sensor i s i nstal l ed
next to the thermostat housi ng (Fi g. 6) and protrudes
i nto the water jacket. The sensor provi des an i nput
vol tage to the powertrai n control modul e (PCM)
rel ati ng cool ant temperature. The PCM uses thi s
i nput al ong wi th i nputs from other sensors to deter-
mi ne i njector pul se wi dth and i gni ti on ti mi ng. As
cool ant temperature vari es, the cool ant temperature
sensor resi stance wi l l change. Thi s change i n resi s-
tance resul ts i n a di fferent i nput vol tage to the PCM.
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
ENGINE COOLANT TEMPERATURE SENSOR 4. 0L
ENGINE PCM INPUT
The engi ne cool ant temperature sensor i s i nstal l ed
i n the thermostat housi ng (Fi g. 7) and protrudes i nto
the water jacket. The sensor provi des an i nput vol t-
age to the powertrai n control modul e (PCM) rel ati ng
cool ant temperature. The PCM uses thi s i nput al ong
wi th i nputs from other sensors to determi ne i njector
pul se wi dth and i gni ti on ti mi ng. As cool ant tempera-
ture vari es, the cool ant temperature sensors resi s-
tance changes. The change i n resi stance resul ts i n a
di fferent i nput vol tage to the PCM.
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
Refer to Open Loop/Cl osed Loop Modes of Opera-
ti on i n thi s secti on of the group for more i nformati on.
Fig. 4 Crankshaft Position Sensor5.2L/
5.9LEngines
GROMMET
MOUNTING BOLTS (2)
CRANKSHAFT POSITION SENSOR
Fig. 5 Crankshaft Position Sensor4.0LEngine
PIGTAIL HARNESS TO DIS- TRIBUTOR SIDE OF ENGINE
CRANKSHAFT POSITION SENSOR
Fig. 6 Engine Coolant Temperature Sensor5.2L/
5.9LEngines
GENERATOR COOLANT TEMPERATURE SENSOR A/C COM- PRESSOR
ZG FUEL SYSTEM 14 - 33
DESCRIPTION AND OPERATION (Continued)
GENERATOR OUTPUT PCM INPUT
Provi des a chargi ng system vol tage i nput to the
Powertrai n Control Modul e (PCM). I t i s sensed at the
battery i nput to the PCM.
OXYGEN SENSOR (O2S) PCM INPUT
Two heated O2S sensors are used. The sensors pro-
duce vol tages from 0 to 1 vol t, dependi ng upon the
oxygen content of the exhaust gas i n the exhaust
mani fol d. When a l arge amount of oxygen i s present
(caused by a l ean ai r/fuel mi xture), the sensors pro-
duces a l ow vol tage. When there i s a l esser amount
present (ri ch ai r/fuel mi xture) i t produces a hi gher
vol tage. By moni tori ng the oxygen content and con-
verti ng i t to el ectri cal vol tage, the sensors act as a
ri ch-l ean swi tch.
I n Cl osed Loop operati on, the PCM moni tors the
O2S sensor i nput (al ong wi th other i nputs) and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2 sensor
i nput. The PCM adjusts i njector pul se wi dth based
on preprogrammed (fi xed) val ues and i nputs from
other sensors.
The oxygen sensors are equi pped wi th a heati ng
el ement that keeps the sensors at proper operati ng
temperature duri ng al l operati ng modes. Mai ntai ni ng
correct sensor temperature at al l ti mes al l ows the
system to enter i nto cl osed l oop operati on sooner.
Al so, i t al l ows the system to remai n i n cl osed l oop
operati on duri ng peri ods of extended i dl e.
The Automati c Shutdown (ASD) rel ay suppl i es bat-
tery vol tage to both the upstream and downstream
heated oxygen sensors. The oxygen sensors are
equi pped wi th a heati ng el ement. The heati ng el e-
ments reduce the ti me requi red for the sensors to
reach operati ng temperature.
UPSTREAM HEATED OXYGEN SENSOR
The upstream O2S sensor i s l ocated near the i nl et
end of the catal yti c converter. I t provi des an i nput
vol tage to the PCM. The i nput tel l s the PCM the oxy-
gen content of the exhaust gas. The PCM uses thi s
i nformati on to fi ne tune the ai r/fuel rati o by adjust-
i ng i njector pul se wi dth.
DOWNSTREAM HEATED OXYGEN SENSOR
The downstream heated oxygen sensor i s l ocated
near the outl et end of the catal yti c converter. The
downstream heated oxygen sensor i nput i s used to
detect catal yti c convertor deteri orati on. As the con-
vertor deteri orates, the i nput from the downstream
sensor begi ns to match the upstream sensor i nput
except for a sl i ght ti me del ay. By compari ng the
downstream heated oxygen sensor i nput to the i nput
from the upstream sensor, the PCM cal cul ates cata-
l yti c convertor effi ci ency.
When the catal yti c converter effi ci ency drops bel ow
emi ssi on standards, the PCM stores a di agnosti c
troubl e code and i l l umi nates the Mal functi on I ndi ca-
tor Lamp (MI L). For more i nformati on, refer to
Group 25, Emi ssi on Control Systems.
IGNITION CIRCUIT SENSE PCM INPUT
The i gni ti on ci rcui t sense i nput tel l s the Power-
trai n Control Modul e (PCM) the i gni ti on swi tch has
energi zed the i gni ti on ci rcui t. Refer to the wi ri ng di a-
grams for ci rcui t i nformati on.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
5. 2L/5. 9L ENGINES PCM INPUT
The i ntake mani fol d ai r temperature sensor i s
i nstal l ed i n the i ntake mani fol d wi th the sensor el e-
ment extendi ng i nto the ai r stream (Fi g. 8). The sen-
sor provi des an i nput vol tage to the powertrai n
control modul e (PCM) i ndi cati ng i ntake mani fol d ai r
temperature. The i nput i s used al ong wi th i nputs
from other sensors to determi ne i njector pul se wi dth.
As the temperature of the ai r-fuel stream i n the
mani fol d vari es, the sensor resi stance changes. Thi s
resul ts i n a di fferent i nput vol tage to the PCM.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
4. 0L ENGINE PCM INPUT
The i ntake mani fol d ai r temperature sensor i s
i nstal l ed i n the i ntake mani fol d wi th the sensor el e-
ment extendi ng i nto the ai r stream (Fi g. 9). The sen-
sor provi des an i nput vol tage to the powertrai n
control modul e (PCM) i ndi cati ng i ntake mani fol d ai r
temperature. The i nput i s used al ong wi th i nputs
from other sensors to determi ne i njector pul se wi dth.
As the temperature of the ai r-fuel stream i n the
mani fol d vari es, the sensor resi stance changes. Thi s
resul ts i n a di fferent i nput vol tage to the PCM.
Fig. 7 Engine Coolant Temperature Sensor
4.0LEngineTypical
ENGINE COOLANT TEMPERATURE SENSOR ELECTRICAL CONNECTOR
14 - 34 FUEL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
LEAK DETECTION PUMP (SWITCH) SENSE PCM
INPUT
Provi des an i nput to the PCM that the l eak detec-
ti on pump (LDP) has been acti vated. Refer to Group
25, Emi ssi on Control System for LDP i nformati on.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR 5. 2L/5. 9L ENGINES PCM INPUT
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d. I t provi des an i nput vol tage to the
powertrai n control modul e (PCM). As engi ne l oad
changes, mani fol d pressure vari es. The change i n
mani fol d pressure causes MAP sensor vol tage to
change. The change i n MAP sensor vol tage resul ts i n
a di fferent i nput vol tage to the PCM. The i nput vol t-
age l evel suppl i es the PCM wi th i nformati on about
ambi ent barometri c pressure duri ng engi ne start-up
(cranki ng) and engi ne l oad whi l e the engi ne i s run-
ni ng. The PCM uses thi s i nput al ong wi th i nputs
from other sensors to adjust ai r-fuel mi xture.
The MAP sensor i s mounted on the si de of the
engi ne throttl e body (Fi g. 10). The sensor i s con-
nected to the throttl e body wi th a rubber L-shaped
fi tti ng.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR 4. 0L ENGINE PCM INPUT
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d. I t provi des an i nput vol tage to the
powertrai n control modul e (PCM). As engi ne l oad
changes, mani fol d pressure vari es. The change i n
mani fol d pressure causes MAP sensor vol tage to
change. The change i n MAP sensor vol tage resul ts i n
a di fferent i nput vol tage to the PCM. The i nput vol t-
age l evel suppl i es the PCM wi th i nformati on about
ambi ent barometri c pressure duri ng engi ne start-up
(cranki ng) and engi ne l oad whi l e the engi ne i s run-
ni ng. The PCM uses thi s i nput al ong wi th i nputs
from other sensors to adjust ai r-fuel mi xture.
The MAP sensor i s mounted on the si de of the
engi ne throttl e body (Fi g. 9). The sensor i s connected
to the throttl e body wi th a rubber L-shaped fi tti ng.
OIL PRESSURE SENSOR PCM INPUT
Sends a si gnal from the oi l pressure sendi ng uni t
to the Powertrai n Control Modul e (PCM) rel ati ng to
engi ne oi l pressure.
OUTPUT SHAFT SPEED SENSOR PCM INPUT
Thi s sensor generates a si gnal to the PCM rel ati ng
to the speed of the transmi ssi on mai n dri ve shaft.
Fig. 8 Intake Manifold Air Temperature Sensor
5.2L/5.9LV-8 EnginesTypical
INTAKE MANIFOLD AIR TEMPERATURE SENSOR GENERATOR
Fig. 9 Throttle Body Sensor Locations4.0LEngine
IDLE AIR CONTROL PAS- SAGE INLET
IDLE AIR CONTROL MOTOR
Fig. 10 MAP and Throttle PositionSensor Location
5.2L/5.9L Engines
MAP SENSOR
IDLE AIR CONTROL MOTOR
THROTTLE POSITION SEN- SOR
ZG FUEL SYSTEM 14 - 35
DESCRIPTION AND OPERATION (Continued)
Thi s i nput i s used wi th 4speed el ectroni c transmi s-
si ons onl y.
OVERDRIVE/OVERRIDE SWITCH-PCM INPUT
On vehi cl es equi pped wi th an automati c transmi s-
si on and overdri ve, the powertrai n control modul e
(PCM) regul ates the 3-4 overdri ve up-shi ft and down-
shi ft through the overdri ve sol enoi d. Thi s sol enoi d i s
l ocated i n the transmi ssi on. An overdri ve/overri de
push-button swi tch i s l ocated on the i nstrument
panel .
The overdri ve/overri de push-button swi tch i s nor-
mal l y open (overdri ve al l owed) when the l amp i s not
i l l umi nated. I t momentari l y cl oses (overdri ve not
al l owed) when the operator presses the swi tch and
the l amp i s i l l umi nated. Overdri ve wi l l revert to ON
(l amp off) each ti me the i gni ti on swi tch i n turned on.
The transmi ssi on downshi fts i f the operator presses
the overri de swi tch whi l e i n overdri ve.
Refer to Group 21 for more transmi ssi on i nforma-
ti on.
SENSOR RETURN PCM INPUT
Sensor Return provi des a l ow noi se ground refer-
ence for al l system sensors.
SIGNAL GROUND PCM INPUT
Si gnal ground provi des a l ow noi se ground to the
data l i nk connector.
SPEED CONTROL SWITCHES PCM INPUT
Two separate speed control swi tch modul es are
mounted on the steeri ng wheel to the l eft and ri ght
si de of the dri vers ai rbag modul e. Wi thi n the two
swi tch modul es, fi ve momentary contact swi tches,
supporti ng seven di fferent speed control functi ons
are used. The outputs from these swi tches are fi l -
tered i nto one i nput. The Powertrai n Control Modul e
(PCM) determi nes whi ch output has been appl i ed
through resistive multiplexing. The i nput ci rcui t
vol tage i s measured by the PCM to determi ne whi ch
swi tch functi on has been sel ected.
A speed control i ndi cator l amp, l ocated on the
i nstrument panel cl uster i s energi zed by the PCM vi a
the CCD Bus. Thi s occurs when speed control system
power has been turned ON, and the engi ne i s run-
ni ng.
The two swi tch modul es are l abel ed: ON/OFF, SET,
RESUME/ACCEL, CANCEL and COAST. Refer to
Group 8H, Speed Control System for more i nforma-
ti on.
TRANSMISSION PARK/NEUTRAL SWITCH PCM
INPUT
The park/neutral swi tch i s l ocated on the transmi s-
si on housi ng and provi des an i nput to the powertrai n
control modul e (PCM). Thi s wi l l i ndi cate that the
automati c transmi ssi on i s i n Park, Neutral or a dri ve
gear sel ecti on. Thi s i nput i s used to determi ne i dl e
speed (varyi ng wi th gear sel ecti on), fuel i njector
pul se wi dth, i gni ti on ti mi ng advance and vehi cl e
speed control operati on. Refer to Group 21, Transmi s-
si ons, for testi ng, repl acement and adjustment i nfor-
mati on.
TRANSMISSION GOVERNOR PRESSURE
SENSOR PCM INPUT
Provi des a si gnal proporti onal to the transmi ssi on
governor pressure. I t provi des feedback for control of
the governor pressure sol enoi d, whi ch regul ates
transmi ssi on governor pressure. Thi s i nput i s used
wi th 4speed el ectroni c transmi ssi ons onl y.
TRANSMISSION TEMPERATURE SENSOR PCM
INPUT
Thi s i nput i s used i n the shi ft operati on for
4speed el ectroni c transmi ssi ons onl y. The tempera-
ture data i s used for: torque converter cl utch opera-
ti on, overdri ve shi ft, l ow temperature shi ft
compensati on, wi de open throttl e shi ft strategy and
governor pressure transducer cal i brati on.
THROTTLE POSITION SENSOR (TPS) 5. 2L/5. 9L
ENGINES PCM INPUT
The throttl e posi ti on sensor (TPS) i s mounted on
the throttl e body (Fi g. 10). The TPS i s a vari abl e
resi stor that provi des the powertrai n control modul e
(PCM) wi th an i nput si gnal (vol tage) that represents
throttl e bl ade posi ti on. The sensor i s connected to the
throttl e bl ade shaft. As the posi ti on of the throttl e
bl ade changes, the resi stance of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .25
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.8 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
THROTTLE POSITION SENSOR (TPS) 4. 0L
ENGINE PCM INPUT
The throttl e posi ti on sensor (TPS) i s mounted on
the throttl e body (Fi g. 9). The TPS i s a vari abl e resi s-
tor that provi des the powertrai n control modul e
(PCM) wi th an i nput si gnal (vol tage) that represents
throttl e bl ade posi ti on. The sensor i s connected to the
throttl e bl ade shaft. As the posi ti on of the throttl e
bl ade changes, the resi stance of the TPS changes.
14 - 36 FUEL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .25
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.8 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
VEHICLE SPEED AND DISTANCE SENSOR PCM
INPUT
The vehi cl e speed sensor i s l ocated on the speed-
ometer pi ni on gear adapter (Fi g. 11) or (Fi g. 12). The
pi ni on gear adapter i s l ocated on the extensi on hous-
i ng of the transmi ssi on (dri vers si de2WD), or on
the transfer case (4WD). The sensor i nput i s used by
the powertrai n control modul e (PCM) to determi ne
vehi cl e speed and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
Under decel erati on condi ti ons, the PCM adjusts
the i dl e ai r control (I AC) motor to mai ntai n a desi red
MAP val ue. Under i dl e condi ti ons, the PCM adjusts
the I AC motor to mai ntai n a desi red engi ne speed.
POWER GROUND
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng powertrai n control modul e
(PCM) l oads:
Generator fi el d wi ndi ng
Fuel i njectors
I gni ti on coi l
Certai n rel ays/sol enoi ds
AIR CONDITIONING (A/C) CLUTCH RELAY PCM
OUTPUT
The A/C rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated i n the engi ne com-
partment (Fi g. 13). Refer to l abel on PDC cover for
rel ay l ocati on.
The powertrai n control modul e (PCM) acti vates the
A/C compressor through the A/C cl utch rel ay. The
PCM regul ates A/C compressor operati on by swi tch-
i ng the ground ci rcui t for the A/C cl utch rel ay on and
off.
When the PCM recei ves a request for A/C from A/C
evaporator swi tch, i t wi l l adjust i dl e ai r control (I AC)
motor posi ti on. Thi s i s done to i ncrease i dl e speed.
The PCM wi l l then acti vate the A/C cl utch through
the A/C cl utch rel ay. The PCM adjusts i dl e ai r control
(I AC) stepper motor posi ti on to compensate for
i ncreased engi ne l oad from the A/C compressor.
By swi tchi ng the ground path for the rel ay on and
off, the PCM i s abl e to cycl e the A/C compressor
Fig. 11 Vehicle Speed Sensor Location2WD
Typical
SENSOR ELEC- TRICAL CON- NECTOR TRANSMIS- SION EXTENSION HOUSING VEHICLE SPEED SENSOR
Fig. 12 Vehicle Speed Sensor Location4WD
Typical
SENSOR ELECTRICAL CON- NECTOR 4WD TRANSFER CASE EXTENSION VEHICLE SPEED SENSOR
ZG FUEL SYSTEM 14 - 37
DESCRIPTION AND OPERATION (Continued)
cl utch. Thi s i s based on changes i n engi ne operati ng
condi ti ons. I f, duri ng A/C operati on, the PCM senses
abnormal l y l ow i dl e speeds i t wi l l de-energi ze the
rel ay. Thi s prevents A/C cl utch engagement. The
rel ay wi l l remai n de-energi zed unti l the i dl e speed
i ncreases. The PCM wi l l al so de-energi ze the rel ay i f
cool ant temperature exceeds 125C (257F) or l ow or
hi gh system pressure exi sts.
AUTO SHUTDOWN (ASD) RELAY PCM OUTPUT
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 13).
The ASD suppl i es battery vol tage to the fuel i njec-
tors, i gni ti on coi l and both oxygen (O2S) sensor heat-
i ng el ements. The ground ci rcui t for the coi l i n the
ASD rel ay i s control l ed by the powertrai n control
modul e (PCM). The PCM operates the rel ay by
swi tchi ng the ground ci rcui t on and off.
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS
The Powertrai n Control Modul e (PCM) sends cer-
tai n output si gnal s through the CCD bus ci rcui ts.
These si gnal s are used to control certai n i nstrument
panel l ocated i tems and to determi ne certai n i denti -
fi cati on numbers.
Refer to Group 8E, I nstrument Panel and Gauges
for addi ti onal i nformati on.
DATA LINK CONNECTOR PCM INPUT AND
OUTPUT
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the powertrai n control modul e (PCM).
The data l i nk connector i s l ocated under the i nstru-
ment panel to the l eft of the steeri ng col umn (Fi g.
14). For operati on of the DRB scan tool , refer to the
appropri ate Powertrai n Di agnosti c Procedures ser-
vi ce manual .
DUTY CYCLE EVAP PURGE SOLENOID VALVE-PCM
OUTPUT
Refer to Group 25, Emi ssi on Control System for
i nformati on.
FUEL INJECTORS 5. 2L/5. 9L ENGINES PCM
OUTPUT
The fuel i njectors are attached to the fuel rai l (Fi g.
15). 5.2L/5.9L V-8 engi nes use ei ght i njectors.
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Duri ng start up, battery vol tage i s suppl i ed to the
i njectors through the ASD rel ay. When the engi ne i s
operati ng, vol tage i s suppl i ed by the chargi ng sys-
tem. The PCM determi nes i njector pul se wi dth based
on vari ous i nputs.
Fig. 13 Power Distribution Center (PDC)
POWER DISTRIBUTION CEN- TER
Fig. 14 Data Link Connector Location
HEADLAMPSWITCH DATA LINK CONNECTOR (LEFT SIDE OF COLUMN ABOVE BRAKE PEDAL)
14 - 38 FUEL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
FUEL INJECTORS 4. 0L ENGINE PCM OUTPUT
Si x i ndi vi dual fuel i njectors are used wi th the 4.0L
6-cyl i nder engi ne. The i njectors are attached to the
fuel rai l (Fi g. 16).
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Duri ng start up, battery vol tage i s suppl i ed to the
i njectors through the ASD rel ay. When the engi ne i s
operati ng, vol tage i s suppl i ed by the chargi ng sys-
tem. The PCM determi nes i njector pul se wi dth based
on vari ous i nputs.
FUEL PUMP RELAY-PCM OUTPUT
The PCM energi zes the el ectri c fuel pump through
the fuel pump rel ay. Battery vol tage i s appl i ed to the
fuel pump rel ay when the i gni ti on key i s ON. The
rel ay i s energi zed when a ground si gnal i s provi ded
by the PCM.
The fuel pump wi l l operate for approxi matel y one
second unl ess the engi ne i s operati ng or the starter
motor i s engaged.
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 13).
GENERATOR FIELD SOURCE (+) PCM OUTPUT
Thi s output from the Powertrai n Control Modul e
(PCM) regul ates chargi ng system vol tage to the gen-
erator fi el d source (+) ci rcui t. The vol tage range i s
12.9 to 15.0 vol ts. Jeep model s of previ ous years had
used the ASD rel ay to appl y the 12 vol t + power sup-
pl y to the generator fi el d source (+) ci rcui t. Refer to
Groups 8A and 8C for chargi ng system i nformati on.
GENERATOR FIELD DRIVER (-) PCM OUTPUT
Thi s output from the Powertrai n Control Modul e
(PCM) regul ates chargi ng system ground control to
the generator fi el d dri ver (-) ci rcui t. Refer to Groups
8A and 8C for chargi ng system i nformati on.
GENERATOR LAMP PCM OUTPUT
I f the powertrai n control modul e (PCM) senses a
l ow chargi ng condi ti on i n the chargi ng system, i t wi l l
i l l umi nate the generator l amp (i f equi pped) on the
i nstrument panel . Thi s i s done through the CCD Bus
ci rcui ts. For exampl e, duri ng l ow i dl e wi th al l acces-
sori es turned on, the l amp may momentari l y go on.
Once the PCM corrects i dl e speed to a hi gher rpm,
the l amp wi l l go out. Refer to Groups 8A and 8C for
chargi ng system i nformati on.
IDLE AIR CONTROL (IAC) MOTOR 5. 2L/5. 9L
ENGINES PCM OUTPUT
The I AC motor i s mounted to the back of the throt-
tl e body (Fi g. 10) and i s control l ed by the powertrai n
control modul e (PCM).
The throttl e body has an ai r control passage that
provi des ai r for the engi ne at i dl e (the throttl e pl ate
i s cl osed). The I AC motor pi ntl e protrudes i nto the
ai r control passage (Fi g. 17) and regul ates ai r fl ow
through i t. Based on vari ous sensor i nputs, the pow-
Fig. 15 Fuel Injectors5.2L/5.9L EnginesTypical
FUEL RAIL FUEL INJECTOR HAR- NESS CONNECTORS FUEL INJECTOR
Fig. 16 Fuel Injectors4.0L Engine
FUEL PRESSURE TEST PORT (IF EQUIPPED) FUEL INJECTOR NUMBEREDTAG FUEL RAIL FUEL RAIL MOUNTING BOLTS
ZG FUEL SYSTEM 14 - 39
DESCRIPTION AND OPERATION (Continued)
ertrai n control modul e (PCM) adjusts engi ne i dl e
speed by movi ng the I AC motor pi ntl e i n and out of
the ai r control passage. The I AC motor i s posi ti oned
when the i gni ti on key i s turned to the On posi ti on.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the PCM.
IDLE AIR CONTROL (IAC) MOTOR 4. 0L
ENGINE PCM OUTPUT
The I AC motor i s mounted on the throttl e body
(Fi g. 9) and i s control l ed by the powertrai n control
modul e (PCM).
The throttl e body has an ai r control passage that
provi des ai r for the engi ne at i dl e (the throttl e pl ate
i s cl osed). The I AC motor pi ntl e protrudes i nto the
ai r control passage and regul ates ai r fl ow through i t.
Based on vari ous sensor i nputs, the powertrai n con-
trol modul e (PCM) adjusts engi ne i dl e speed by mov-
i ng the I AC motor pi ntl e i n and out of the ai r control
passage. The I AC motor i s posi ti oned when the i gni -
ti on key i s turned to the On posi ti on.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the PCM.
IGNITION COIL 5. 2L/5. 9L ENGINES PCM
OUTPUT
System vol tage i s suppl i ed to the i gni ti on coi l pos-
i ti ve termi nal . The powertrai n control modul e (PCM)
operates the i gni ti on coi l . Base (initial) ignition
timing is not adjustable. The PCM adjusts i gni ti on
ti mi ng to meet changi ng engi ne operati ng condi ti ons.
The i gni ti on coi l i s l ocated near the front of the
ri ght cyl i nder head (Fi g. 18).
Refer to Group 8D, I gni ti on System for addi ti onal
i nformati on.
IGNITION COIL 4. 0L ENGINES PCM OUTPUT
System vol tage i s suppl i ed to the i gni ti on coi l pos-
i ti ve termi nal . The powertrai n control modul e (PCM)
operates the i gni ti on coi l . Base (initial) ignition
timing is not adjustable. The PCM adjusts i gni ti on
ti mi ng to meet changi ng engi ne operati ng condi ti ons.
The i gni ti on coi l i s l ocated near the di stri butor
(Fi g. 19).
Refer to Group 8D, I gni ti on System for addi ti onal
i nformati on.
LEAK DETECTION PUMP PCM OUTPUT
Certai n Cal i forni a model s are equi pped wi th a l eak
detecti on pump (LDP). The LDP i s acti vated through
Fig. 17 Throttle Body Air ControlPassage5.2L/5.9L
EnginesTypical
MAP SENSOR
RUBBER FITTING
IDLE AIR PASSAGE
Fig. 18 Ignition Coil5.2L/5.9L EnginesTypical
COIL MOUNT- ING BOLTS ACCESSORY DRIVE BELT TENSIONER COIL CONNEC- TOR IGNITION COIL
Fig. 19 Ignition Coil4.0L Engine
ELECTRICAL CONNECTOR
IGNITION COIL
MOUNTING BOLTS (2)
14 - 40 FUEL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
thi s PCM output. Refer to Group 25, Emi ssi on Con-
trol System for addi ti onal i nformati on.
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMP PCM OUTPUT
The mal functi on i ndi cator l amp i l l umi nates each
ti me the i gni ti on key i s turned on. I t wi l l stay on for
approxi matel y three seconds as a bul b test. The l amp
i s di spl ayed on the i nstrument panel as the CHECK
ENGI NE l amp.
I f the powertrai n control modul e (PCM) recei ves an
i ncorrect si gnal , or no si gnal from certai n sensors or
emi ssi on rel ated systems, the l amp i s turned on. Thi s
i s a warni ng that the PCM has recorded a system or
sensor mal functi on. I n some cases, when a probl em i s
decl ared, the PCM wi l l go i nto a l i mp-i n mode. Thi s
i s an attempt to keep the system operati ng. I t si gnal s
an i mmedi ate need for servi ce.
The l amp can al so be used to di spl ay a Di agnosti c
Troubl e Code (DTC). Cycl e the i gni ti on swi tch
On-Off-On-Off-On wi thi n three seconds and any
codes stored i n the PCM memory wi l l be di spl ayed.
Thi s i s done i n a seri es of fl ashes representi ng di gi ts.
The l amp i s al so used to detect certai n engi ne mi s-
fi res. Refer to Group 25, Emi ssi on Control System for
more i nformati on.
OVERDRIVE LAMP PCM OUTPUT
Thi s ci rcui t control s a si gnal for the operati on of
the i nstrument panel mounted push-button overdri ve
l amp swi tch. When the l amp i s i l l umi nated, the over-
dri ve i s di sengaged.
SPEED CONTROL SOLENOIDS PCM OUTPUT
Speed control operati on i s regul ated by the power-
trai n control modul e (PCM). The PCM control s the
vacuum to the throttl e actuator through the speed
control vacuum and vent sol enoi ds. Refer to Group
8H for Speed Control I nformati on.
TACHOMETER PCM OUTPUT
The powertrai n control modul e (PCM) suppl i es
engi ne rpm val ues to the i nstrument cl uster tachom-
eter. Refer to Group 8E for tachometer i nformati on.
THREE-FOUR SHIFT SOLENOID PCM OUTPUT
Thi s output i s used to control the transmi ssi on
three-four shi ft sol enoi d. I t i s used on 4speed el ec-
troni cal l y control l ed automati c transmi ssi ons onl y.
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID
PCM OUTPUT
Thi s ci rcui t control s operati on of the transmi ssi on
mounted torque convertor cl utch (TCC) sol enoi d used
for torque convertor engagement.
The powertrai n control modul e (PCM) wi l l deter-
mi ne when to engage and di sengage the sol enoi d by
moni tori ng vehi cl e mi l es per hour (mph) versus the
output vol tage of the throttl e posi ti on sensor. Al so
needed are vari ous i nputs from:
Transmi ssi on temperature sensor
Output shaft speed sensor
Modul e ti mer
Engi ne rpm
MAP sensor
Brake swi tch
MANUAL TRANSMISSION
I f equi pped wi th a manual transmi ssi on, thi s PCM
output wi l l control operati on of the shi ft i ndi cator
l amp (i f equi pped wi th l amp). The l amp i s control l ed
by the powertrai n control modul e (PCM). The l amp
i l l umi nates on the i nstrument panel to i ndi cate when
the dri ver shoul d shi ft to the next hi ghest gear for
best fuel economy. The PCM wi l l turn the l amp OFF
after 3 to 5 seconds i f the shi ft of gears i s not per-
formed. The l amp wi l l remai n off unti l vehi cl e stops
accel erati ng and i s brought back to range of up-shi ft
l amp operati on. Thi s wi l l al so happen i f vehi cl e i s
shi fted i nto fi fth gear.
The i ndi cator l amp i s normal l y i l l umi nated when
the i gni ti on swi tch i s turned on and i t i s turned off
when the engi ne i s started up. Wi th the engi ne run-
ni ng, the l amp i s turned ON/OFF dependi ng upon
engi ne speed and l oad.
TRANSMISSION RELAY PCM OUTPUT
The output to thi s rel ay provi des battery vol tage to
the overdri ve (OD), torque converter cl utch (TCC)
and governor pressure sol enoi ds. Once battery vol t-
age i s appl i ed to the sol enoi ds, they are i ndi vi dual l y
acti vated by the PCM through OD, TCC and gover-
nor pressure outputs. The rel ay i s l ocated i n the
Power Di stri buti on Center (PDC). Refer to l abel on
PDC cover for rel ay l ocati on.
GOVERNOR PRESSURE SOLENOID PCM OUTPUT
Thi s sol enoi d regul ates the transmi ssi on fl ui d l i ne
pressure to produce the governor pressure necessary
for transmi ssi on shi ft control . I t i s used on 4speed
el ectroni c transmi ssi ons onl y.
THROTTLE BODY 5. 2L/5. 9L ENGINES
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body (Fi g. 20). Fuel
does not enter the i ntake mani fol d through the throt-
tl e body. Fuel i s sprayed i nto the mani fol d by the fuel
i njectors. The throttl e body i s mounted on the i ntake
mani fol d. I t contai ns an ai r control passage (Fi g. 21)
control l ed by an i dl e ai r control (I AC) motor. The ai r
control passage i s used to suppl y ai r for i dl e condi -
ZG FUEL SYSTEM 14 - 41
DESCRIPTION AND OPERATION (Continued)
ti ons. A throttl e val ve (pl ate) i s used to suppl y ai r for
above i dl e condi ti ons.
The throttl e posi ti on sensor (TPS), i dl e ai r control
(I AC) motor and mani fol d absol ute pressure sensor
(MAP) are attached to the throttl e body. The accel er-
ator pedal cabl e, speed control cabl e and transmi s-
si on control cabl e (when equi pped) are connected to
the throttl e arm.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the PCM.
THROTTLE BODY 4. 0L ENGINE
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body (Fi g. 22). Fuel
does not enter the i ntake mani fol d through the throt-
tl e body. Fuel i s sprayed i nto the mani fol d by the fuel
i njectors. The throttl e body i s mounted on the i ntake
mani fol d. I t contai ns an ai r control passage (Fi g. 22)
control l ed by an i dl e ai r control (I AC) motor. The ai r
control passage i s used to suppl y ai r for i dl e condi -
ti ons. A throttl e val ve (pl ate) i s used to suppl y ai r for
above i dl e condi ti ons.
The throttl e posi ti on sensor (TPS), i dl e ai r control
(I AC) motor and mani fol d absol ute pressure sensor
(MAP) are attached to the throttl e body. The accel er-
ator pedal cabl e, speed control cabl e and transmi s-
si on control cabl e (when equi pped) are connected to
the throttl e arm.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the PCM.
DIAGNOSIS AND TESTING
VISUAL INSPECTION 5. 2L/5. 9L ENGINES
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
hel p spot these faul ts and save unnecessary test and
Fig. 20 Throttle Body5.2L/5.9L EnginesTypical
THROTTLE BODY MOUNTING BOLTS (4) THROTTLE BODY
Fig. 21 Air Control Passage5.2L/5.9LEngines
Typical
MAP SENSOR
RUBBER FITTING
IDLE AIR PASSAGE
Fig. 22 Throttle Body4.0LEngine
IDLE AIR CONTROL PAS- SAGE INLET
IDLE AIR CONTROL MOTOR
14 - 42 FUEL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy that the three 32way el ectri cal connec-
tors are ful l y i nserted i nto the connector of the pow-
ertrai n control modul e (PCM) (Fi g. 23).
(2) I nspect the battery cabl e connecti ons. Be sure
that they are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ai r condi ti oni ng
compressor cl utch rel ay (i f equi pped). I nspect the
ASD rel ay connecti ons. I nspect starter motor rel ay
connecti ons. I nspect rel ays for si gns of physi cal dam-
age and corrosi on. The rel ays are l ocated i n the
Power Di stri buti on Center (PDC) (Fi g. 24). Refer to
l abel on PDC cover for rel ay l ocati on.
(4) I nspect i gni ti on coi l connecti ons. Veri fy that
coi l secondary cabl e i s fi rml y connected to coi l (Fi g.
25).
(5) Veri fy that di stri butor cap i s correctl y attached
to di stri butor. Be sure that spark pl ug cabl es are
fi rml y connected to the di stri butor cap and the spark
pl ugs are i n thei r correct fi ri ng order. Be sure that
coi l cabl e i s fi rml y connected to di stri butor cap and
coi l . Be sure that camshaft posi ti on sensor wi re con-
nector (at the di stri butor) i s fi rml y connected to har-
ness connector. I nspect spark pl ug condi ti on. Refer to
Group 8D, I gni ti on. Connect vehi cl e to an osci l l oscope
and i nspect spark events for foul ed or damaged spark
pl ugs or cabl es.
(6) Veri fy that generator output wi re, generator
connector and ground wi re are fi rml y connected to
the generator.
(7) I nspect the system body grounds for l oose or
di rty connecti ons. Refer to Group 8, Wi ri ng for
ground l ocati ons.
(8) Veri fy posi ti ve crankcase venti l ati on (PCV)
val ve operati on. Refer to Group 25, Emi ssi on Control
System for addi ti onal i nformati on. Veri fy PCV val ve
hose i s fi rml y connected to PCV val ve and mani fol d
(Fi g. 26).
(9) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(10) Veri fy that hose connecti ons to al l ports of
vacuum fi tti ngs on i ntake mani fol d are ti ght and not
l eaki ng.
(11) I nspect accel erator cabl e, transmi ssi on throt-
tl e cabl e (i f equi pped) and crui se control cabl e con-
Fig. 23 Powertrain Control Module (PCM)
PCM (3) 32WAY CONNECTORS
Fig. 24 Power Distribution Center (PDC)
POWER DISTRIBUTION CEN- TER
Fig. 25 Ignition Coil5.2L/5.9L Engines
COIL MOUNT- ING BOLTS ACCESSORY DRIVE BELT TENSIONER COIL CONNEC- TOR IGNITION COIL
ZG FUEL SYSTEM 14 - 43
DIAGNOSIS AND TESTING (Continued)
necti ons (i f equi pped). Check thei r connecti ons to the
throttl e arm of throttl e body for any bi ndi ng or
restri cti ons.
(12) I f equi pped wi th vacuum brake booster, veri fy
that vacuum booster hose i s fi rml y connected to fi t-
ti ng on i ntake mani fol d. Al so check connecti on to
brake vacuum booster.
(13) I nspect the ai r cl eaner i nl et and ai r cl eaner
el ement for di rt or restri cti ons.
(14) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(15) Veri fy that the i ntake mani fol d ai r tempera-
ture sensor wi re connector i s fi rml y connected to har-
ness connector (Fi g. 27).
(16) Veri fy that MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 28). Al so veri fy
that rubber L-shaped fi tti ng from MAP sensor to the
throttl e body i s fi rml y connected (Fi g. 29).
(17) Veri fy that fuel i njector wi re harness connec-
tors are fi rml y connected to i njectors i n the correct
order. Each harness connector i s numeri cal l y tagged
wi th the i njector number (I NJ 1, I NJ 2 etc.) of i ts
correspondi ng fuel i njector and cyl i nder number.
(18) Veri fy harness connectors are fi rml y con-
nected to i dl e ai r control (I AC) motor, throttl e posi -
ti on sensor (TPS) and mani fol d absol ute pressure
(MAP) sensor (Fi g. 28).
(19) Veri fy that wi re harness connector i s fi rml y
connected to the engi ne cool ant temperature sensor
(Fi g. 30).
(20) Rai se and support the vehi cl e.
(21) Veri fy that both the upstream and down-
stream oxygen sensor wi re connectors are fi rml y con-
Fig. 26 PCV Valve Hose Connections5.2L/
5.9LEnginesTypical
PCV VALVE PCV VALVE HOSE CONNEC- TIONS
Fig. 27 Air Temperature Sensor5.2L/5.9LEngines
INTAKE MANIFOLD AIR TEMPERATURE SENSOR GENERATOR
Fig. 28 Sensor and IAC Motor Location5.2L/
5.9LEngines
MAP SENSOR
IDLE AIR CONTROL MOTOR
THROTTLE POSITION SEN- SOR
Fig. 29 Rubber L-Shaped FittingMAPSensor-to-
Throttle Body
MAP SENSOR
RUBBER FITTING
IDLE AIR PASSAGE
14 - 44 FUEL SYSTEM ZG
DIAGNOSIS AND TESTING (Continued)
nected to the sensors. I nspect sensors and connectors
for damage (Fi g. 31) or (Fi g. 32).
(22) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(23) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(24) I f equi pped wi th automati c transmi ssi on, ver-
i fy that el ectri cal harness i s fi rml y connected to park/
neutral swi tch. Refer to Automati c Transmi ssi on
secti on of Group 21.
(25) Veri fy that the el ectri cal harness connector i s
fi rml y connected to the vehi cl e speed sensor (Fi g. 33)
or (Fi g. 34).
(26) Veri fy that fuel pump/gauge sender uni t wi re
connector i s fi rml y connected to harness connector.
(27) I nspect fuel hoses at fuel pump/gauge sender
uni t for cracks or l eaks.
(28) I nspect transmi ssi on torque convertor housi ng
(automati c transmi ssi on) or cl utch housi ng (manual
transmi ssi on) for damage to ti mi ng ri ng on dri ve
pl ate/fl ywheel .
(29) Veri fy that battery cabl e and sol enoi d feed
wi re connecti ons to the starter sol enoi d are ti ght and
cl ean. I nspect for chaffed wi res or wi res rubbi ng up
agai nst other components.
Fig. 30 Engine Coolant Temperature Sensor5.2L/
5.9LEnginesTypical
GENERATOR COOLANT TEMPERATURE SENSOR A/C COM- PRESSOR
Fig. 31 Upstream Oxygen Sensor5.2L.5.9LEngines
UPSTREAM OXYGEN SENSOR
Fig. 32 Downstream Oxygen Sensor5.2L/
5.9LEngines
CATALYTIC CONVERTER
CLIP
DOWNSTREAM OXYGEN SENSOR
Fig. 33 Vehicle Speed Sensor2WDTypical
SENSOR ELEC- TRICAL CON- NECTOR TRANSMIS- SION EXTENSION HOUSING VEHICLE SPEED SENSOR
ZG FUEL SYSTEM 14 - 45
DIAGNOSIS AND TESTING (Continued)
VISUAL INSPECTION 4. 0L ENGINE
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
hel p spot these faul ts and save unnecessary test and
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy that the three 32way el ectri cal connec-
tors are ful l y i nserted i nto the connector of the pow-
ertrai n control modul e (PCM) (Fi g. 35).
(2) I nspect the battery cabl e connecti ons. Be sure
that they are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ai r condi ti oni ng
compressor cl utch rel ay (i f equi pped). I nspect the
ASD rel ay connecti ons. I nspect starter motor rel ay
connecti ons. I nspect rel ays for si gns of physi cal dam-
age and corrosi on. The rel ays are l ocated i n the
Power Di stri buti on Center (PDC) (Fi g. 36). Refer to
l abel on PDC cover for rel ay l ocati on.
(4) I nspect i gni ti on coi l connecti ons. Veri fy that
coi l secondary cabl e i s fi rml y connected to coi l (Fi g.
37).
(5) Veri fy that di stri butor cap i s correctl y attached
to di stri butor. Be sure that spark pl ug cabl es are
fi rml y connected to the di stri butor cap and the spark
pl ugs are i n thei r correct fi ri ng order (Fi g. 38). Be
sure that coi l cabl e i s fi rml y connected to di stri butor
cap and coi l . Be sure that camshaft posi ti on sensor
wi re connector (at the di stri butor) i s fi rml y connected
to harness connector. I nspect spark pl ug condi ti on.
Refer to Group 8D, I gni ti on. Connect vehi cl e to an
osci l l oscope and i nspect spark events for foul ed or
damaged spark pl ugs or cabl es.
(6) Veri fy that generator output wi re, generator
connector and ground wi re are fi rml y connected to
the generator.
(7) I nspect the system body grounds for l oose or
di rty connecti ons. Refer to Group 8, Wi ri ng for
ground l ocati ons.
Fig. 34 Vehicle Speed Sensor4WDTypical
SENSOR ELECTRICAL CON- NECTOR 4WD TRANSFER CASE EXTENSION VEHICLE SPEED SENSOR
Fig. 35 Powertrain Control Module (PCM)
PCM (3) 32WAY CONNECTORS
Fig. 36 Power Distribution Center (PDC)
POWER DISTRIBUTION CEN- TER
14 - 46 FUEL SYSTEM ZG
DIAGNOSIS AND TESTING (Continued)
(8) Veri fy crankcase venti l ati on (CCV) operati on.
Refer to Group 25, Emi ssi on Control System for addi -
ti onal i nformati on.
(9) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(10) Veri fy that hose connecti ons to al l ports of
vacuum fi tti ngs on i ntake mani fol d are ti ght and not
l eaki ng.
(11) I nspect accel erator cabl e, transmi ssi on throt-
tl e cabl e (i f equi pped) and crui se control cabl e con-
necti ons (i f equi pped). Check thei r connecti ons to the
throttl e arm of throttl e body for any bi ndi ng or
restri cti ons.
(12) I f equi pped wi th vacuum brake booster, veri fy
that vacuum booster hose i s fi rml y connected to fi t-
ti ng on i ntake mani fol d. Al so check connecti on to
brake vacuum booster.
(13) I nspect the ai r cl eaner i nl et and ai r cl eaner
el ement for di rt or restri cti ons.
(14) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(15) Veri fy that the i ntake mani fol d ai r tempera-
ture sensor wi re connector i s fi rml y connected to har-
ness connector (Fi g. 39).
(16) Veri fy that MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 39). Al so veri fy
that rubber L-shaped fi tti ng from MAP sensor to the
throttl e body i s fi rml y connected (Fi g. 40).
(17) Veri fy that fuel i njector wi re harness connec-
tors are fi rml y connected to i njectors i n the correct
order. Each harness connector i s numeri cal l y tagged
wi th the i njector number (I NJ 1, I NJ 2 etc.) of i ts
correspondi ng fuel i njector and cyl i nder number.
Fig. 37 Ignition Coil4.0L Engine
ELECTRICAL CONNECTOR
IGNITION COIL
MOUNTING BOLTS (2)
Fig. 38 Distributor and Wiring4.0LEngine
COIL CAMSHAFT POSITION SEN- SOR CONNECTOR DISTRIBUTOR
Fig. 39 Sensor Locations4.0L Engine
IDLE AIR CONTROL PAS- SAGE INLET
IDLE AIR CONTROL MOTOR
Fig. 40 Rubber L-Shaped FittingMAPSensor-to-
Throttle Body
THROTTLE BODY
MAP SENSOR
RUBBER FITTING
( )
ZG FUEL SYSTEM 14 - 47
DIAGNOSIS AND TESTING (Continued)
(18) Veri fy harness connectors are fi rml y con-
nected to i dl e ai r control (I AC) motor and throttl e
posi ti on sensor (TPS) (Fi g. 39).
(19) Veri fy that wi re harness connector i s fi rml y
connected to the engi ne cool ant temperature sensor
(Fi g. 41).
(20) Rai se and support the vehi cl e.
(21) Veri fy that both of the oxygen sensor wi re
connectors are fi rml y connected to the sensors.
I nspect sensors and connectors for damage (Fi g. 42)
or (Fi g. 43).
(22) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(23) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(24) I f equi pped wi th automati c transmi ssi on, ver-
i fy that el ectri cal harness i s fi rml y connected to park/
neutral swi tch. Refer to Automati c Transmi ssi on
secti on of Group 21.
(25) Veri fy that the el ectri cal harness connector i s
fi rml y connected to the vehi cl e speed sensor (Fi g. 44)
or (Fi g. 45).
(26) Veri fy that fuel pump/gauge sender uni t wi re
connector i s fi rml y connected to harness connector.
(27) I nspect fuel hoses at fuel pump/gauge sender
uni t for cracks or l eaks.
(28) I nspect transmi ssi on torque convertor housi ng
(automati c transmi ssi on) or cl utch housi ng (manual
transmi ssi on) for damage to ti mi ng ri ng on dri ve
pl ate/fl ywheel .
Fig. 41 Engine Coolant Temp. Sensor4.0LShown
ENGINE COOLANT TEMPERATURE SENSOR ELECTRICAL CONNECTOR
Fig. 42 Upstream Oxygen Sensor4.0LEngine
EXHAUST DOWN PIPE OXYGEN SEN- SOR
Fig. 43 Downstream Oxygen Sensor4.0LEngine
CATALYTIC CONVERTER
CLIP
DOWNSTREAM OXYGEN SENSOR
Fig. 44 Vehicle Speed Sensor2WDTypical
SENSOR ELEC- TRICAL CON- NECTOR TRANSMIS- SION EXTENSION HOUSING VEHICLE SPEED SENSOR
14 - 48 FUEL SYSTEM ZG
DIAGNOSIS AND TESTING (Continued)
(29) Veri fy that battery cabl e and sol enoi d feed
wi re connecti ons to the starter sol enoi d are ti ght and
cl ean. I nspect for chaffed wi res or wi res rubbi ng up
agai nst other components.
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays . The termi nal s on
the bottom of each rel ay are numbered (Fi g. 46).
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to group 8W, Wi r-
i ng Di agrams.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST 5. 2L. 5. 9L ENGINES
To perform a compl ete test of MAP sensor (Fi g. 47)
and i ts ci rcui try, refer to DRB scan tool and appro-
Fig. 45 Vehicle Speed Sensor4WDTypical
SENSOR ELECTRICAL CON- NECTOR 4WD TRANSFER CASE EXTENSION VEHICLE SPEED SENSOR
Fig. 46 ASD and Fuel Pump Relay Terminals
TERMINAL LEGEND NUMBER IDENTIFICATION COMMON FEED
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
ZG FUEL SYSTEM 14 - 49
DIAGNOSIS AND TESTING (Continued)
pri ate Powertrai n Di agnosti cs Procedures manual . To
test the MAP sensor onl y, refer to the fol l owi ng:
(1) I nspect the rubber L-shaped fi tti ng from the
MAP sensor to the throttl e body (Fi g. 48). Repai r as
necessary.
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
(2) Test the MAP sensor output vol tage at the
MAP sensor connector between termi nal s A and B
(Fi g. 49). Wi th the i gni ti on swi tch ON and the engi ne
OFF, output vol tage shoul d be 4-to-5 vol ts. The vol t-
age shoul d drop to 1.5-to-2.1 vol ts wi th a hot, neutral
i dl e speed condi ti on.
(3) Test powertrai n control modul e (PCM) cavi ty
A-27 for the same vol tage descri bed above to veri fy
the wi re harness condi ti on. Repai r as necessary.
(4) Test MAP sensor suppl y vol tage at sensor con-
nector between termi nal s A and C (Fi g. 49) wi th the
i gni ti on ON. The vol tage shoul d be approxi matel y 5
vol ts (0.5V). Fi ve vol ts (0.5V) shoul d al so be at
cavi ty A-17 of the PCM wi re harness connector.
Repai r or repl ace the wi re harness as necessary.
(5) Test the MAP sensor ground ci rcui t at sensor
connector termi nal A (Fi g. 49) and PCM connector
A-4. Repai r the wi re harness i f necessary.
Refer to Group 8W, Wi ri ng Di agrams for cavi ty
l ocati ons.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST 4. 0L ENGINE
To perform a compl ete test of MAP sensor (Fi g. 50)
and i ts ci rcui try, refer to DRB scan tool and appro-
pri ate Powertrai n Di agnosti cs Procedures manual . To
test the MAP sensor onl y, refer to the fol l owi ng:
(1) I nspect the rubber L-shaped fi tti ng from the
MAP sensor to the throttl e body (Fi g. 51). Repai r as
necessary.
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
(2) Test the MAP sensor output vol tage at the
MAP sensor connector between termi nal s A and B
(Fi g. 49). Wi th the i gni ti on swi tch ON and the engi ne
OFF, output vol tage shoul d be 4-to-5 vol ts. The vol t-
age shoul d drop to 1.5-to-2.1 vol ts wi th a hot, neutral
i dl e speed condi ti on.
Fig. 47 MAP Sensor5.2L/5.9L EnginesTypical
MAP SENSOR
IDLE AIR CONTROL MOTOR
THROTTLE POSITION SEN- SOR
Fig. 48 Rubber L-Shaped FittingMAPSensor-to-
Throttle Body
MAP SENSOR
RUBBER FITTING
IDLE AIR PASSAGE
Fig. 49 MAP Sensor Connector TerminalsTypical
A = GROUND B = OUTPUT VOLTAGE SIGNAL C = 5VOLT SUPPLY MAP SENSOR
14 - 50 FUEL SYSTEM ZG
DIAGNOSIS AND TESTING (Continued)
(3) Test powertrai n control modul e (PCM) cavi ty
A-27 for the same vol tage descri bed above to veri fy
the wi re harness condi ti on. Repai r as necessary.
(4) Test MAP sensor suppl y vol tage at sensor con-
nector between termi nal s A and C (Fi g. 49) wi th the
i gni ti on ON. The vol tage shoul d be approxi matel y 5
vol ts (0.5V). Fi ve vol ts (0.5V) shoul d al so be at
cavi ty A-17 of the PCM wi re harness connector.
Repai r or repl ace the wi re harness as necessary.
(5) Test the MAP sensor ground ci rcui t at sensor
connector termi nal A (Fi g. 49) and PCM connector
A-4. Repai r the wi re harness i f necessary.
Refer to Group 8W, Wi ri ng Di agrams for cavi ty
l ocati ons.
OXYGEN (O2S) SENSORS 5. 2L/5. 9L ENGINES
To perform a compl ete test of the O2S sensors and
thei r ci rcui try, refer to the DRB scan tool and appro-
pri ate Powertrai n Di agnosti cs Procedures manual . To
test the O2S sensors onl y, refer to the fol l owi ng:
The upstream O2S sensor i s l ocated on the exhaust
pi pe (Fi g. 52).
The downstream O2S sensor i s l ocated on the out-
l et end of the catal yti c converter (Fi g. 53).
Fig. 50 Sensor Location4.0L Engine
IDLE AIR CONTROL PAS- SAGE INLET
IDLE AIR CONTROL MOTOR
Fig. 51 Rubber L-Shaped FittingMAPSensor-to-
Throttle Body
THROTTLE BODY
MAP SENSOR
RUBBER FITTING
( )
Fig. 52 Upstream Oxygen SensorLocation5.2L/
5.9L Engines
UPSTREAM OXYGEN SENSOR
Fig. 53 Downstream Oxygen Sensor Location
AllEngines
CATALYTIC CONVERTER
CLIP
DOWNSTREAM OXYGEN SENSOR
ZG FUEL SYSTEM 14 - 51
DIAGNOSIS AND TESTING (Continued)
Each O2S heati ng el ement can be tested wi th an
ohmmeter as fol l ows:
Di sconnect the O2S sensor connector. Connect the
ohmmeter test l eads across the whi te wi re termi nal s
of the sensor connector. Resi stance shoul d be
between 4.5 .5 ohms and 7 ohms. Repl ace the sen-
sor i f the ohmmeter di spl ays an i nfi ni ty (open) read-
i ng.
OXYGEN (O2S) SENSORS 4. 0L ENGINE
To perform a compl ete test of the O2S sensors and
thei r ci rcui try, refer to the DRB scan tool and appro-
pri ate Powertrai n Di agnosti cs Procedures manual . To
test the O2S sensors onl y, refer to the fol l owi ng:
The upstream O2S sensor i s l ocated on the exhaust
pi pe (Fi g. 54).
The downstream O2S sensor i s l ocated on the out-
l et end of the catal yti c converter (Fi g. 53).
Each O2S heati ng el ement can be tested wi th an
ohmmeter as fol l ows:
Di sconnect the O2S sensor connector. Connect the
ohmmeter test l eads across the whi te wi re termi nal s
of the sensor connector. Resi stance shoul d be
between 4.5 .5 ohms and 7 ohms. Repl ace the sen-
sor i f the ohmmeter di spl ays an i nfi ni ty (open) read-
i ng.
CAMSHAFT AND CRANKSHAFT POSITION
SENSORS
Refer to Group 8D, I gni ti on System for i nforma-
ti on.
ENGINE COOLANT TEMPERATURE SENSOR 5. 2L/
5. 9L ENGINES
To perform a compl ete test of the engi ne cool ant
temperature sensor and i ts ci rcui try, refer to DRB
scan tool and appropri ate Powertrai n Di agnosti cs
Procedures manual . To test the sensor onl y, refer to
the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor (Fi g. 55).
(2) Engines with air conditioning: When
removi ng the connector from sensor, do not pul l
di rectl y on wi ri ng harness. Fabri cate an L-shaped
hook tool from a coat hanger (approxi matel y ei ght
i nches l ong). Pl ace the hook part of tool under the
connector for removal . The connector i s snapped onto
the sensor. I t i s not equi pped wi th a l ock type tab.
(3) Test the resi stance of the sensor wi th a hi gh
i nput i mpedance (di gi tal ) vol t-ohmmeter. The resi s-
tance (as measured across the sensor termi nal s)
shoul d be as shown i n the Cool ant Temperature Sen-
sor/I ntake Ai r Temperature Sensor resi stance chart.
Repl ace the sensor i f i t i s not wi thi n the range of
resi stance speci fi ed i n the chart.
(4) Test conti nui ty of the wi re harness between the
PCM wi re harness connector and the cool ant sensor
connector termi nal s. Refer to Group 8, Wi ri ng for ter-
mi nal /cavi ty l ocati ons. Repai r the wi re harness i f an
open ci rcui t i s i ndi cated.
(5) After tests are compl eted, connect el ectri cal
connector to sensor. The sensor connector i s symmet-
ri cal (not i ndexed). I t can be i nstal l ed to the sensor
i n ei ther di recti on.
ENGINE COOLANT TEMPERATURE SENSOR 4. 0L
ENGINE
To perform a compl ete test of the engi ne cool ant
temperature sensor and i ts ci rcui try, refer to DRB
scan tool and appropri ate Powertrai n Di agnosti cs
Procedures manual . To test the sensor onl y, refer to
the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor (Fi g. 56).
Fig. 54 Upstream Oxygen Sensor Location
4.0LEngine
EXHAUST DOWN PIPE OXYGEN SEN- SOR
Fig. 55 Engine Coolant Temperature Sensor5.2L/
5.9LEngines
GENERATOR COOLANT TEMPERATURE SENSOR A/C COM- PRESSOR
14 - 52 FUEL SYSTEM ZG
DIAGNOSIS AND TESTING (Continued)
(2) Test the resi stance of the sensor wi th a hi gh
i nput i mpedance (di gi tal ) vol t-ohmmeter. The resi s-
tance (as measured across the sensor termi nal s)
shoul d be as shown i n the previ ous Cool ant Temper-
ature Sensor/I ntake Ai r Temperature Sensor resi s-
tance chart. Repl ace the sensor i f i t i s not wi thi n the
range of resi stance speci fi ed i n the chart.
(3) Test conti nui ty of the wi re harness between the
PCM wi re harness connector and the cool ant sensor
connector termi nal s. Refer to Group 8, Wi ri ng for ter-
mi nal /cavi ty l ocati ons. Repai r the wi re harness i f an
open ci rcui t i s i ndi cated.
IDLE AIR CONTROL (IAC) MOTOR 5. 2L/5. 9L
ENGINES
To perform a compl ete test of the I AC motor and
i ts ci rcui try, refer to DRB scan tool and appropri ate
Powertrai n Di agnosti cs Procedures manual .
IDLE AIR CONTROL (IAC) MOTOR 4. 0L ENGINE
To perform a compl ete test of the I AC motor and
i ts ci rcui try, refer to DRB scan tool and appropri ate
Powertrai n Di agnosti cs Procedures manual .
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
5. 2L/5. 9L ENGINE
To perform a compl ete test of the i ntake mani fol d
ai r temperature sensor and i ts ci rcui try, refer to DRB
tester and appropri ate Powertrai n Di agnosti cs Proce-
dures manual . To test the sensor onl y, refer to the
fol l owi ng:
(1) Di sconnect the wi re harness connector from the
i ntake mani fol d ai r temperature sensor (Fi g. 57).
(2) Test the resi stance of the sensor wi th an i nput
i mpedance (di gi tal ) vol t-ohmmeter. The resi stance (as
measured across the sensor termi nal s) shoul d be as
shown i n the previ ous Cool ant Temperature sensor/
I ntake Ai r Temperature sensor resi stance chart.
Repl ace the sensor i f i t i s not wi thi n the range of
resi stance speci fi ed i n the chart.
(3) Test the resi stance of the wi re harness. Do thi s
between the PCM wi re harness connector A-15 and
the sensor connector termi nal . Al so check between
PCM connector A-4 to the sensor connector termi nal .
Repai r the wi re harness as necessary i f the resi s-
tance i s greater than 1 ohm.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
4. 0L ENGINE
To perform a compl ete test of the i ntake mani fol d
ai r temperature sensor and i ts ci rcui try, refer to DRB
SENSOR RESISTANCE (OHMS)COOLANT
TEMPERATURE SENSOR/INTAKE AIR
TEMPERATURE SENSOR
TEMPERATURE RESISTANCE (OHMS) MIN MAX
Fig. 56 Engine Coolant Temperature Sensor
4.0LEngine
ENGINE COOLANT TEMPERATURE SENSOR ELECTRICAL CONNECTOR
Fig. 57 Air Temperature Sensor5.2L/5.9LEngines
INTAKE MANIFOLD AIR TEMPERATURE SENSOR GENERATOR
ZG FUEL SYSTEM 14 - 53
DIAGNOSIS AND TESTING (Continued)
tester and appropri ate Powertrai n Di agnosti cs Proce-
dures manual . To test the sensor onl y, refer to the
fol l owi ng:
(1) Di sconnect the wi re harness connector from the
i ntake mani fol d ai r temperature sensor (Fi g. 58).
(2) Test the resi stance of the sensor wi th an i nput
i mpedance (di gi tal ) vol t-ohmmeter. The resi stance (as
measured across the sensor termi nal s) shoul d be as
shown i n the previ ous Cool ant Temperature Sensor/
I ntake Ai r Temperature Sensor resi stance chart.
Repl ace the sensor i f i t i s not wi thi n the range of
resi stance speci fi ed i n the chart.
(3) Test the resi stance of the wi re harness. Do thi s
between the PCM wi re harness connector A-15 and
the sensor connector termi nal . Al so check between
PCM connector A-4 to the sensor connector termi nal .
Repai r the wi re harness as necessary i f the resi s-
tance i s greater than 1 ohm.
VEHICLE SPEED SENSOR
To perform a compl ete test of the sensor and i ts
ci rcui try, refer to DRB scan tool and appropri ate
Powertrai n Di agnosti cs Procedures manual .
THROTTLE POSITION SENSOR (TPS) 5. 2L/5. 9L
ENGINES
To perform a compl ete test of the TPS and i ts ci r-
cui try, refer to the DRB scan tool and appropri ate
Powertrai n Di agnosti cs Procedures manual . To test
the TPS onl y, refer to the fol l owi ng:
The TPS (Fi g. 59) can be tested wi th a di gi tal vol t-
meter. The center el ectri cal termi nal of the TPS i s
the output termi nal .
Wi th the i gni ti on key i n the ON posi ti on, check the
TPS output vol tage at the center termi nal wi re of the
connector. Check thi s at i dl e (throttl e pl ate cl osed)
and at wi de open throttl e (WOT). At i dl e, TPS output
vol tage shoul d be greater than .350 mi l l i vol ts but
l ess than 900 mi l l i vol ts. At wi de open throttl e, TPS
output vol tage must be l ess than 4.5 vol ts. The out-
put vol tage shoul d i ncrease gradual l y as the throttl e
pl ate i s sl owl y opened from i dl e to WOT.
THROTTLE POSITION SENSOR (TPS) 4. 0L
ENGINE
To perform a compl ete test of the TPS (Fi g. 58) and
i ts ci rcui try, refer to the DRB scan tool and appropri -
ate Powertrai n Di agnosti cs Procedures manual . To
test the TPS onl y, refer to the fol l owi ng:
The TPS can be tested wi th a di gi tal vol tmeter.
The center termi nal of the TPS i s the output termi -
nal .
Wi th the i gni ti on key i n the ON posi ti on, check the
TPS output vol tage at the center termi nal wi re of the
connector. Check thi s at i dl e (throttl e pl ate cl osed)
and at wi de open throttl e (WOT). At i dl e, TPS output
vol tage shoul d be greater than .350 mi l l i vol ts and
l ess than 900 mi l l i vol ts. At wi de open throttl e, TPS
output vol tage must be l ess than 4.5 vol ts. The out-
put vol tage shoul d i ncrease gradual l y as the throttl e
pl ate i s sl owl y opened from i dl e to WOT.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
5.2L/5.9L ENGINE
The fol l owi ng test procedure has been devel oped to
check throttl e body cal i brati ons for correct i dl e condi -
ti ons. The procedure shoul d be used to di agnose the
Fig. 58 Intake Manifold Air TemperatureSensor
4.0L Engine
IDLE AIR CONTROL PAS- SAGE INLET
IDLE AIR CONTROL MOTOR
Fig. 59 TPS5.2L/5.9L Engines
MAP SENSOR
IDLE AIR CONTROL MOTOR
THROTTLE POSITION SEN- SOR
14 - 54 FUEL SYSTEM ZG
DIAGNOSIS AND TESTING (Continued)
throttl e body for condi ti ons that may cause i dl e prob-
l ems. This procedure should be used only after
normal diagnostic procedures have failed to
produce results that indicate a throttle body
related problem. Be sure to check for proper
operation of the idle air control motor before
performing this test.
A speci al fi xed ori fi ce tool (number 6714) (Fi g. 60)
must be used for the fol l owi ng test.
(1) Start the engi ne and bri ng to operati ng tem-
perature. Be sure al l accessori es are off before per-
formi ng thi s test.
(2) Shut off the engi ne and remove the ai r duct at
throttl e body.
(3) Di sconnect the vacuum l i ne at the PCV val ve
(Fi g. 61).
(4) I nstal l the 0.185 i nch ori fi ce tool (number 6714)
i nto the di sconnected vacuum l i ne i n pl ace of the
PCV val ve (Fi g. 61).
(5) Di sconnect the i dl e purge vacuum l i ne from fi t-
ti ng at throttl e body. Thi s vacuum l i ne i s l ocated on
the front of throttl e body next to the MAP sensor
(Fi g. 62). Cap the fi tti ng at throttl e body after vac-
uum l i ne has been removed.
(6) Connect the DRB scan tool to the 16way data
l i nk connector. Thi s connector i s l ocated under the
i nstrument panel to the l eft of the steeri ng col umn.
Refer to the appropri ate Powertrai n Di agnosti c Pro-
cedures servi ce manual for DRB operati on.
(7) Start the engi ne and al l ow to warm up.
(8) Usi ng the DRB scan tool , scrol l through the
menus as fol l ows: sel ectStand Al one DRB I I I , sel ect
19941997 Di agnosti cs, sel ectEngi ne, sel ectSys-
tem Test, sel ectMi ni mum Ai r Fl ow.
(9) The DRB scan tool wi l l count down to stabi l i ze
the i dl e rpm and di spl ay the mi ni mum ai r fl ow i dl e
rpm. The i dl e rpm shoul d be between 500 and 900
rpm. I f the i dl e speed i s outsi de of these speci fi ca-
ti ons, repl ace the throttl e body. Refer to Throttl e
Body i n the Component Removal /I nstal l ati on secti on
of thi s group.
(10) Di sconnect the DRB scan tool from the vehi -
cl e.
(11) Remove cap from i dl e purge fi tti ng at throttl e
body and i nstal l vacuum l i ne.
(12) Remove ori fi ce tool and connect vacuum l i ne
to PCV val ve.
(13) I nstal l ai r duct to throttl e body.
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN (ASD) RELAY
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 63). Refer to l abel on PDC cover
for rel ay l ocati on.
Fig. 60 Fixed Orifice Tool
SPECIAL TOOL 6714
Fig. 61 Install Orifice Tool
PCV VALVE VACUUM LINE ORIFICE TOOL
Fig. 62 Idle Purge Line
FRONT OF ENGINE THROTTLE BODY PURGE VACUUM LINE
ZG FUEL SYSTEM 14 - 55
DIAGNOSIS AND TESTING (Continued)
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
FUEL PUMP RELAY
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 63). Refer to l abel on PDC
cover for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
THROTTLE BODY 5. 2L/5. 9L ENGINES
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the powertrai n control modul e (PCM).
REMOVAL
(1) Remove the ai r duct at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 64).
(3) Remove vacuum l i ne at throttl e body.
(4) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(5) Remove four throttl e body mounti ng bol ts (Fi g.
65).
(6) Remove throttl e body from i ntake mani fol d.
(7) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
INSTALLATION
(1) Cl ean the mati ng surfaces of the throttl e body
and the i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 23
Nm (200 i n. l bs.) torque.
(5) I nstal l control cabl es.
(6) I nstal l vacuum l i ne to throttl e body.
(7) I nstal l el ectri cal connectors.
(8) I nstal l ai r duct at throttl e body.
Fig. 63 Power Distribution Center (PDC) Location
POWER DISTRIBUTION CEN- TER
Fig. 64 Sensor Electrical Connectors5.2L/
5.9LEnginesTypical
MAP SENSOR
IDLE AIR CONTROL MOTOR
THROTTLE POSITION SEN- SOR
14 - 56 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
THROTTLE BODY 4. 0L ENGINE
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the powertrai n control modul e (PCM).
REMOVAL
(1) Remove the ai r cl eaner duct at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 66).
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(4) Remove four throttl e body mounti ng bol ts.
(5) Remove throttl e body from i ntake mani fol d.
(6) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
INSTALLATION
(1) Cl ean the mati ng surfaces of the throttl e body
and the i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 11
Nm (100 i n. l bs.) torque.
(5) I nstal l control cabl es.
(6) I nstal l el ectri cal connectors.
(7) I nstal l ai r duct at throttl e body.
THROTTLE POSITION SENSOR (TPS) 5. 2L/5. 9L
ENGINES
REMOVAL
The TPS i s l ocated on the si de of the throttl e body.
(1) Remove ai r duct at throttl e body.
(2) Di sconnect TPS el ectri cal connector.
(3) Remove two TPS mounti ng bol ts (Fi g. 67).
(4) Remove TPS from throttl e body.
INSTALLATION
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 68). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs.
The TPS wi l l be under sl i ght tensi on when rotated.
Fig. 65 Throttle Body Mounting Bolts5.2L/
5.9LEnginesTypical
THROTTLE BODY MOUNTING BOLTS (4) THROTTLE BODY
Fig. 66 Throttle Body and Sensor Locations
4.0LEngine
IDLE AIR CONTROL PAS- SAGE INLET
IDLE AIR CONTROL MOTOR
Fig. 67 TPS Mounting Bolts5.2L/5.9LEngines
Typical
THROTTLE POSITION SEN- SOR
MOUNTING SCREWS
ZG FUEL SYSTEM 14 - 57
REMOVAL AND INSTALLATION (Continued)
(1) I nstal l the TPS and two retai ni ng bol ts.
(2) Ti ghten bol ts to 7 Nm (60 i n. l bs.) torque.
(3) Manual l y operate the throttl e control l ever by
hand to check for any bi ndi ng of the TPS.
(4) Connect TPS el ectri cal connector to TPS.
(5) I nstal l ai r duct at throttl e body.
THROTTLE POSITION SENSOR (TPS) 4. 0L
ENGINE
The TPS i s mounted to the throttl e body.
REMOVAL
(1) Di sconnect TPS el ectri cal connector.
(2) Remove TPS mounti ng screws (Fi g. 69).
(3) Remove TPS.
INSTALLATION
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 70). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs).
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l the TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate the throttl e (by hand) to
check for any TPS bi ndi ng before starti ng the engi ne.
IDLE AIR CONTROL (IAC) MOTOR 5. 2L/5. 9L
ENGINES
The I AC motor i s l ocated on the back of the throt-
tl e body.
REMOVAL
(1) Remove ai r duct at throttl e body.
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 71).
(4) Remove I AC motor from throttl e body.
Fig. 68 Installation5.2L/5.9L EnginesTypical
THROTTLE BODY THROTTLE POSITION SENSOR THROTTLE SHAFT SOCKET LOCATING TANGS
Fig. 69 TPS Mounting Screws4.0L Engine
MOUNTING SCREWS
TPS
Fig. 70 Throttle Position Sensor Installation
4.0LEngine
TANGS THROTTLE SHAFT THROTTLE BODY TPS
Fig. 71 Mounting Bolts (Screws)IACMotor5.2L/
5.9L EnginesTypical
MOUNTING SCREWS IDLE SPEED MOTOR
14 - 58 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r duct at throttl e body.
IDLE AIR CONTROL (IAC) MOTOR 4. 0L ENGINE
The I AC motor i s l ocated on the si de of the throttl e
body.
REMOVAL
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 72).
(4) Remove I AC motor from throttl e body.
INSTALLATION
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r cl eaner tube to throttl e body.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR 5. 2L/5. 9L ENGINES
The MAP sensor i s l ocated on the front of the
throttl e body (Fi g. 73). An L-shaped rubber fi tti ng i s
used to connect the MAP sensor to throttl e body (Fi g.
74).
REMOVAL
(1) Remove ai r duct at throttl e body.
(2) Di sconnect el ectri cal connector at sensor.
(3) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 74).
(4) Whi l e removi ng MAP sensor, sl i de the vacuum
rubber L-shaped fi tti ng (Fi g. 74) from the throttl e
body.
(5) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
INSTALLATION
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
(4) Connect el ectri cal connector.
(5) I nstal l ai r duct at throttl e body.
Fig. 72 Mounting Bolts (Screws)IACMotor4.0L
Engine
IDLE AIR CONTROL MOTOR
MOUNTING SCREWS
Fig. 73 MAP Sensor Mounting Screws5.2L/
5.9LEngines
MAP SENSOR
FRONT
MOUNTING SCREWS (2)
Fig. 74 MAP Sensor L-Shaped Rubber Fitting5.2L/
5.9LEngines
MAP SENSOR
RUBBER FITTING
IDLE AIR PASSAGE
ZG FUEL SYSTEM 14 - 59
REMOVAL AND INSTALLATION (Continued)
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR 4. 0L ENGINE
The MAP sensor i s mounted to the si de of the
throttl e body (Fi g. 75). An L-shaped rubber fi tti ng i s
used to connect the MAP sensor to throttl e body (Fi g.
76).
REMOVAL
(1) Remove ai r cl eaner i ntake tube at throttl e
body.
(2) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 76).
(3) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 76) from the throttl e body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
INSTALLATION
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
(4) I nstal l ai r cl eaner i ntake tube.
DUTY CYCLE EVAP CANISTER PURGE SOLENOID
Refer to Group 25, Emi ssi on Control System for
removal /i nstal l ati on procedures.
POWERTRAIN CONTROL MODULE (PCM)
The PCM i s l ocated on the cowl panel i n the ri ght/
rear si de of the engi ne compartment (Fi g. 77).
REMOVAL
(1) Di sconnect the negati ve battery cabl e at bat-
tery.
(2) Remove cover over el ectri cal connectors. Cover
snaps onto PCM.
(3) Remove the cool ant reserve/overfl ow tank (one
bol t and two nuts) (Fi g. 78).
(4) Careful l y unpl ug the three 32way connectors
at PCM.
(5) Remove the three PCM mounti ng bol ts (Fi g.
79).
(6) Remove PCM.
Fig. 75 MAP Sensor Location4.0L Engine
IDLE AIR CONTROL PAS- SAGE INLET
IDLE AIR CONTROL MOTOR
Fig. 76 Rubber L-Shaped FittingMAPSensor-to-
Throttle Body4.0L Engine
THROTTLE BODY
MAP SENSOR
RUBBER FITTING
( )
Fig. 77 Powertrain Control Module (PCM) Location
PCM (3) 32WAY CONNECTORS
14 - 60 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Check the pi ns i n the three 32way el ectri cal
connectors for damage. Repai r as necessary.
(2) I nstal l PCM. Ti ghten three mounti ng bol ts to 1
Nm (9 i n. l bs.) torque.
(3) I nstal l three 32way connectors.
(4) I nstal l cover over el ectri cal connectors. Cover
snaps onto PCM.
(5) I nstal l cool ant reserve/overfl ow tank.
(6) Connect negati ve cabl e to battery.
CRANKSHAFT POSITION SENSOR
Refer to Group 8D, I gni ti on System for removal /i n-
stal l ati on procedures.
CAMSHAFT POSITION SENSOR
For removal /i nstal l ati on procedures, refer to Group
8D, I gni ti on System. See Camshaft Posi ti on Sensor.
OXYGEN SENSOR 5. 2L/5. 9L ENGINES
The upstream O2S sensor i s l ocated i n the exhaust
downpi pe. The downstream sensor i s l ocated near
outl et end of catal yti c converter. Refer to (Fi g. 80) or
(Fi g. 81).
REMOVAL
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Rai se and support vehi cl e.
(2) Downstream Sensor Onl y: Di sconnect O2S wi r-
i ng connector cl i p (Fi g. 81) at body. Remove cl i p from
O2S el ectri cal connector and di scard.
(3) Di sconnect O2S pi gtai l harness wi re connector
from mai n connector.
CAUTION: When disconnecting the sensor electri-
cal connector, do not pull directly on wire going
into sensor.
Fig. 78 Coolant Reserve/Overflow Tank Mounting
COOLANT OVERFLOW HOSE COOLANT LEVEL SENSOR COOLANT RESERVE/OVER- FLOW TANK
Fig. 79 Powertrain Control Module (PCM) Mounting
PCM MOUNTING BOLTS (3)
Fig. 80 Upstream Oxygen Sensor Location5.2L/
5.9LEngines
UPSTREAM OXYGEN SENSOR
ZG FUEL SYSTEM 14 - 61
REMOVAL AND INSTALLATION (Continued)
(4) Remove O2S sensor. Snap-On oxygen sensor
wrench (number YA 8875) may be used for removal
and i nstal l ati on.
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
threads of a new oxygen sensor.
(1) I nstal l O2S sensor. Ti ghten to 30 Nm (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector to mai n
wi ri ng harness.
(3) Downstream Sensor Onl y: I nstal l new wi ri ng
connector cl i p i nto O2S el ectri cal connector. Snap
thi s cl i p to body. The O2S pi gtai l harness must be
cl i pped to body to prevent mechani cal damage from
propshaft.
(4) Lower the vehi cl e.
OXYGEN SENSOR 4. 0L ENGINE
The upstream O2S sensor i s l ocated i n the exhaust
downpi pe. The downstream sensor i s l ocated near
outl et end of catal yti c converter. Refer to (Fi g. 82) or
(Fi g. 81).
REMOVAL
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Rai se and support vehi cl e.
(2) Downstream Sensor Onl y: Di sconnect O2S wi r-
i ng connector cl i p (Fi g. 81) at body. Remove cl i p from
O2S el ectri cal connector and di scard.
(3) Di sconnect O2S pi gtai l harness wi re connector
from mai n connector.
CAUTION: When disconnecting the sensor electri-
cal connector, do not pull directly on wire going
into sensor.
(4) Remove O2S sensor. Snap-On oxygen sensor
wrench (number YA 8875) may be used for removal
and i nstal l ati on.
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) I nstal l the O2S sensor. Ti ghten to 30 Nm (22
ft. l bs.) torque.
(2) Connect O2S sensor wi re connector to mai n
wi ri ng harness.
(3) Downstream Sensor Onl y: I nstal l new wi ri ng
connector cl i p i nto O2S el ectri cal connector. Snap
thi s cl i p to body. The O2S pi gtai l harness must be
cl i pped to body to prevent mechani cal damage from
propshaft.
(4) Lower the vehi cl e.
AIR CLEANER HOUSING
REMOVAL
(1) Unl ock cl ean ai r hose cl amp (Fi g. 83) at ai r
cl eaner cover. To unl ock the cl amp, attach adjustabl e
pl i ers to cl amp and rotate pl i ers as shown i n (Fi g.
84). Remove cl ean ai r hose at cover.
(2) Remove crankcase breather/fi l ter hose at ai r
cl eaner cover.
Fig. 81 Downstream Oxygen Sensor Location
AllEngines
CATALYTIC CONVERTER
CLIP
DOWNSTREAM OXYGEN SENSOR
Fig. 82 Upstream Oxygen Sensor Location
4.0LEngine
EXHAUST DOWN PIPE OXYGEN SEN- SOR
14 - 62 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
(3) From under vehi cl e, remove three housi ng nuts
(Fi g. 83).
(4) Rel ease the ai r cl eaner housi ng from the ambi -
ent ai r duct and remove housi ng from vehi cl e.
INSTALLATION
(1) Posi ti on ai r cl eaner housi ng to body and ambi -
ent ai r duct (Fi g. 83).
(2) I nstal l three nuts and ti ghten to 10 Nm (93 i n.
l bs.) torque.
(3) I nstal l crankcase breather/fi l ter hose to cover.
(4) I nstal l cl amp to cover. Compress the cl amp
snugl y wi th adjustabl e pl i ers as shown i n (Fi g. 85).
AIR CLEANER ELEMENT (FILTER)
REMOVAL/INSTALLATION
(1) Pry back the si x cl i ps retai ni ng the ai r cl eaner
cover to the ai r cl eaner housi ng (Fi g. 86).
(2) Li ft the cover up and posi ti on to the si de.
(3) Remove ai r cl eaner el ement.
(4) Cl ean the i nsi de of ai r cl eaner housi ng before
i nstal l i ng new el ement.
(5) Reverse the precedi ng operati on for i nstal l a-
ti on. Be sure the ai r cl eaner cover i s properl y seated
to ai r cl eaner housi ng.
Fig. 83 Air Cleaner5.2L V-8 EngineShown
CLAMPS AIR CLEANER COVER AMBIENT AIR DUCT CLEAN AIR HOSE
Fig. 84 Clamp Removal
CLAMP ADJUSTABLE PLIERS REMOVAL
Fig. 85 Clamp Installation
CLAMP ADJUSTABLE PLI- ERS
Fig. 86 Air Cleaner Element Removal/Installation
COVER AIR FILTER HOUSING CLIPS (6)
ZG FUEL SYSTEM 14 - 63
REMOVAL AND INSTALLATION (Continued)
ENGINE COOLANT TEMPERATURE SENSOR 5. 2L/
5. 9L ENGINES
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
(1) Parti al l y drai n cool i ng system. Refer to Group
7, Cool i ng.
(2) Di sconnect el ectri cal connector from sensor
(Fi g. 87).
(3) Engines with air conditioning: When
removi ng the connector from sensor, do not pul l
di rectl y on wi ri ng harness. Fabri cate an L-shaped
hook tool from a coat hanger (approxi matel y ei ght
i nches l ong). Pl ace the hook part of tool under the
connector for removal . The connector i s snapped onto
the sensor. I t i s not equi pped wi th a l ock type tab.
(4) Remove sensor from i ntake mani fol d.
INSTALLATION
(1) I nstal l sensor.
(2) Ti ghten to 11 Nm (8 ft. l bs.) torque.
(3) Connect el ectri cal connector to sensor. The sen-
sor connector i s symmetri cal (not i ndexed). I t can be
i nstal l ed to the sensor i n ei ther di recti on.
(4) Repl ace any l ost engi ne cool ant. Refer to Group
7, Cool i ng System.
ENGINE COOLANT TEMPERATURE SENSOR 4. 0L
ENGINE
The cool ant temperature sensor i s i nstal l ed i n the
thermostat housi ng (Fi g. 88).
REMOVAL
(1) Parti al l y drai n cool i ng system unti l the cool ant
l evel i s bel ow the cyl i nder head. Observe the WARN-
INGS i n Group 7, Cool i ng.
(2) Di sconnect the cool ant temperature sensor wi re
connector.
(3) Remove the sensor from the thermostat hous-
i ng.
INSTALLATION
(1) Appl y seal ant to sensor threads.
(2) I nstal l cool ant temperature sensor i nto the
thermostat housi ng. Ti ghten to 11 Nm (8 ft. l bs.)
torque.
(3) Connect the wi re connector.
(4) Fi l l the cool i ng system. Refer to Group 7, Cool -
i ng System.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
5. 2L/5. 9L ENGINES
The i ntake mani fol d ai r temperature sensor i s
l ocated i n the front/si de of the i ntake mani fol d (Fi g.
89).
REMOVAL
(1) Di sconnect el ectri cal connector at sensor (Fi g.
89).
(2) Remove sensor from i ntake mani fol d.
INSTALLATION
(1) I nstal l sensor to i ntake mani fol d. Ti ghten to 28
Nm (20 ft. l bs.) torque.
(2) I nstal l el ectri cal connector.
Fig. 87 Engine Coolant Temperature Sensor5.2L/
5.9LEngines
GENERATOR COOLANT TEMPERATURE SENSOR A/C COM- PRESSOR
Fig. 88 Engine Coolant Temperature Sensor
4.0LEngine
ENGINE COOLANT TEMPERATURE SENSOR ELECTRICAL CONNECTOR
14 - 64 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
4. 0L ENGINE
The i ntake mani fol d ai r temperature sensor i s
i nstal l ed i nto the i ntake mani fol d pl enum near the
throttl e body (Fi g. 90).
REMOVAL
(1) Di sconnect the el ectri cal connector from the
sensor.
(2) Remove the sensor from the i ntake mani fol d.
INSTALLATION
(1) I nstal l the sensor i nto the i ntake mani fol d.
Ti ghten the sensor to 28 Nm (20 ft. l bs.) torque.
(2) Connect the el ectri cal connector to the sensor.
VEHICLE SPEED SENSOR
The vehi cl e speed sensor i s l ocated on the speed-
ometer pi ni on gear adapter (Fi g. 91) or (Fi g. 92). The
pi ni on gear adapter i s l ocated on the extensi on hous-
i ng of the transmi ssi on (dri vers si de).
REMOVAL
(1) Rai se and support vehi cl e.
Fig. 89 Air Temperature Sensor5.2L/5.9LEngines
Typical
INTAKE MANIFOLD AIR TEMPERATURE SENSOR GENERATOR
Fig. 90 Intake Air Sensor Location4.0LEngine
IDLE AIR CONTROL PAS- SAGE INLET
IDLE AIR CONTROL MOTOR
Fig. 91 Vehicle Speed Sensor Location2WD
Typical
SENSOR ELEC- TRICAL CON- NECTOR TRANSMIS- SION EXTENSION HOUSING VEHICLE SPEED SENSOR
Fig. 92 Vehicle Speed Sensor Location4WD
Typical
SENSOR ELECTRICAL CON- NECTOR 4WD TRANSFER CASE EXTENSION VEHICLE SPEED SENSOR
ZG FUEL SYSTEM 14 - 65
REMOVAL AND INSTALLATION (Continued)
(2) Di sconnect the el ectri cal connector from the
sensor.
(3) Remove the sensor mounti ng bol t (Fi g. 93).
(4) Remove the sensor (pul l strai ght out) from the
speedometer pi ni on gear adapter (Fi g. 93). Do not
remove the gear adapter from the transmi ssi on.
INSTALLATION
(1) Cl ean the i nsi de of speedometer pi ni on gear
adapter before i nstal l i ng speed sensor.
(2) I nstal l sensor i nto speedometer gear adapter
and i nstal l mounti ng bol t. Before tightening bolt,
verify speed sensor is fully seated (mounted
flush) to speedometer pinion gear adapter.
(3) Ti ghten sensor mounti ng bol t to 2.2 Nm (20 i n.
l bs.) torque.
(4) Connect el ectri cal connector to sensor.
SPECIFICATIONS
VECI LABEL
I f anythi ng di ffers between the speci fi cati ons found
on the Vehi cl e Emi ssi on Control I nformati on (VECI )
l abel and the fol l owi ng speci fi cati ons, use speci fi ca-
ti ons on VECI l abel . The VECI l abel i s l ocated i n the
engi ne compartment.
TORQUE CHART
DESCRIPTION TORQUE
Ai r Cl eaner Housi ng Mount. Nuts . 10 Nm (93 i n. l bs.)
Engi ne Cool ant Temperature
SensorAl l Engi nes . . . . . . . . 11 Nm (96 i n. l bs.)
Fuel Hose Cl amps . . . . . . . . . . . . 1 Nm (10 i n. l bs.)
I AC Motor-To-Throttl e Body
Bol ts . . . . . . . . . . . . . . . . . . . . 7 Nm (60 i n. l bs.)
I ntake Mani fol d Ai r Temp.
ensorAl l Engi nes . . . . . . . . . 28 Nm (20 ft. l bs.)
MAP Sensor Mounti ng
ScrewsAl l Engi nes . . . . . . . . 3 Nm (25 i n. l bs.)
Oxygen SensorAl l Engi nes . . . 30 Nm (22 ft. l bs.)
Powertrai n Control Modul e
Mounti ng Screws . . . . . . . . . . . . 1 Nm (9 i n. l bs.)
Throttl e Body Mounti ng Bol ts
5.2L/5.9L Engi ne . . . . . . . . . 23 Nm (200 i n. l bs.)
Throttl e Body Mounti ng Bol ts
4.0L Engi ne . . . . . . . . . . . . . 11 Nm (100 i n. l bs.)
Throttl e Posi ti on Sensor Mounti ng
ScrewsAl l Engi nes . . . . . . . . 7 Nm (60 i n. l bs.)
Vehi cl e Speed Sensor
Mounti ng Bol t . . . . . . . . . . . . 2.2 Nm (20 i n. l bs.)
Fig. 93 Sensor Removal/Installation
ELECTRICAL CONNECTOR SENSOR MOUNTING BOLT O-RING SPEEDOMETER PINION GEAR SPEEDOMETER PINION GEAR ADAPTER O-RING VEHICLE SPEED SENSOR
14 - 66 FUEL SYSTEM ZG
REMOVAL AND INSTALLATION (Continued)
SPECIAL TOOLS
FUEL SYSTEM
Spanner Wrench6856
Fitting, Air Metering6714
Adapters, Fuel Pressure Test6541,6539, 6631 or
6923
Pump, IM240 EVAP Service Pressure6917
O2S (Oxygen Sensor) Remover/InstallerC-4907
Test Kit, Fuel Pressure5069
Test Kit, Fuel PressureC-4799-B
Fuel Line Removal Tool6782
ZG FUEL SYSTEM 14 - 67
FUEL SYSTEM2.5L DIESEL ENGINE
CONTENTS
page page
FUEL DELIVERY SYSTEM 2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL INJECTION SYSTEM 2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
FUEL REQUIREMENTS2.5L DIESEL . . . . . . . . 2
INTRODUCTION2.5L DIESEL . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION 2. 5L DIESEL
Certai n sensors that are part of the 2.5L di esel
engi ne fuel system are moni tored by the Bosch
engi ne control l er (MSA). Based on i nputs reci eved
from these sensors, the MSA control s the amount of
fuel and the ti mi ng of when i t i s del i vered to the
engi ne. The MSA control l er i s l ocated under the l eft
si de rear seat. The Powertrai n Control Modul e
(PCM) i s mounted to a bracket l ocated i n the ri ght
rear si de of the engi ne compartment behi nd the cool -
ant tank. I t i nterfaces wi th the MSA el ectroni cal l y to
control other components.
The Fuel System consi sts of: the fuel tank, fuel
i njecti on pump (engi ne mounted), fuel fi l ter/water
separator, fuel tank modul e, el ectri cal fuel gauge
sendi ng uni t, gl ow pl ugs, gl ow pl ug rel ay, PCM, and
al l the el ectri cal components that control the fuel
system. I t al so consi sts of fuel tubes/l i nes/hoses and
fi tti ngs, vacuum hoses, and fuel i njector(s).
Fig. 1 PCM Location
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 1
A Fuel Return System. A separate fuel return
system i s used. Thi s wi l l route excess fuel : from the
fuel i njectors; through i ndi vi dual i njector drai n
tubes; through the fuel i njecti on pump overfl ow
val ve; and back to the fuel tank through a separate
fuel l i ne.
The Fuel Tank Assembly consi sts of: the fuel
tank, two pressure rel i ef/rol l over val ves, fuel fi l l er
tube, fuel tank modul e contai ni ng a fuel gauge send-
i ng uni t, and a pressure-vacuum fi l l er cap.
FUEL REQUIREMENTS 2. 5L DIESEL
Refer to the Lubri cati on and Mai ntenance secti on
of thi s manual for i nformati on. Al so refer to the
Owner Manual .
Fig. 2 MSA Controller Location
14 - 2 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
GENERAL INFORMATION (Continued)
FUEL DELIVERY SYSTEM2.5L DIESEL ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . 7
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . 4
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 4
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . 8
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . 5
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . . 4
FUEL SYSTEM PRESSURE WARNING . . . . . . . 3
FUEL TANK MODULE . . . . . . . . . . . . . . . . . . . . 4
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL TUBES/LINES/HOSES AND CLAMPS
LOW-PRESSURE TYPE . . . . . . . . . . . . . . . . . 7
HIGH-PRESSURE FUEL LINES . . . . . . . . . . . . . 7
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 3
QUICK-CONNECT FITTINGSLOW PRESSURE
TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WASTEGATE (TURBOCHARGER) . . . . . . . . . . . 9
DIAGNOSIS AND TESTING
AIR IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . 12
FUEL HEATER RELAY TEST . . . . . . . . . . . . . . 12
FUEL INJECTION PUMP TEST . . . . . . . . . . . . . 13
FUEL INJECTOR SENSOR TEST . . . . . . . . . . . 13
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . 12
FUEL SHUTDOWN SOLENOID TEST . . . . . . . . 13
FUEL SUPPLY RESTRICTIONS . . . . . . . . . . . . 13
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 9
HIGH-PRESSURE FUEL LINE LEAK TEST . . . . 13
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . 9
WASTEGATE (TURBOCHARGER) . . . . . . . . . . 14
SERVICE PROCEDURES
AIR BLEED PROCEDURES . . . . . . . . . . . . . . . 14
FUEL INJECTION PUMP TIMING . . . . . . . . . . . 15
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . 15
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . 16
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . 16
FUEL FILTER/WATER SEPARATOR . . . . . . . . . 16
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . 17
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . 18
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . 21
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . 17
FUEL RESERVOIR MODULE . . . . . . . . . . . . . . 23
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HIGH-PRESSURE LINES . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS
FUEL INJECTOR FIRING SEQUENCE . . . . . . . 25
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . 25
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . 24
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION AND OPERATION
INTRODUCTION
Thi s Fuel Del i very secti on wi l l cover components
not control l ed by the PCM. For components con-
trol l ed by the PCM, refer to the Fuel I njecti on Sys-
tem2.5L Di esel Engi ne secti on of thi s group.
The fuel heater rel ay, fuel heater and fuel gauge
are not operated by the PCM. These components are
control l ed by the i gni ti on (key) swi tch. Al l other fuel
system el ectri cal components necessary to operate
the engi ne are control l ed or regul ated by the PCM.
FUEL SYSTEM PRESSURE WARNING
WARNING: HIGHPRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 45,000 KPA (6526 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGHPRESSURE FUEL LEAKS. INSPECT FOR
HIGHPRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD (Fig. 1). HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 3
FUEL TANK
The fuel tank and tank mounti ng used wi th the
di esel powered engi ne i s the same as used wi th gas-
ol i ne powered model s, al though the fuel tank modul e
i s di fferent.
The fuel tank contai ns the fuel tank modul e and
two rol l over val ves. Two fuel l i nes are routed to the
fuel tank modul e. One l i ne i s used for fuel suppl y to
the fuel fi l ter/water separator. The other i s used to
return excess fuel back to the fuel tank.
The fuel tank modul e contai ns the fuel gauge el ec-
tri cal sendi ng uni t. An electrical fuel pump is not
used with the diesel engine.
FUEL TANK MODULE
An el ectri c fuel pump i s not attached to the fuel
tank modul e for di esel powered engi nes. Fuel i s sup-
pl i ed by the fuel i njecti on pump.
The fuel tank modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 2). The fuel tank modul e contai ns the
fol l owi ng components:
Fuel reservoi r
A separate i n-tank fuel fi l ter
El ectri c fuel gauge sendi ng uni t
Fuel suppl y l i ne connecti on
Fuel return l i ne connecti on
FUEL GAUGE SENDING UNIT
The fuel gauge sendi ng uni t i s attached to the si de
of the fuel pump modul e. The sendi ng uni t consi sts of
a fl oat, an arm, and a vari abl e resi stor (track). The
track i s used to send an el ectri cal si gnal used for fuel
gauge operati on.
As the fuel l evel i ncreases, the fl oat and arm move
up. Thi s decreases the sendi ng uni t resi stance, caus-
i ng the PCM to send a si gnal to the fuel gauge on the
i nstrument panel to read ful l . As the fuel l evel
decreases, the fl oat and arm move down. Thi s
i ncreases the sendi ng uni t resi stance, causi ng the
PCM to send a si gnal to the fuel gauge on the i nstru-
ment panel to read empty.
FUEL FILTER/WATER SEPARATOR
The fuel fi l ter/water separator assembl y i s l ocated
i n the engi ne compartment near the strut tower (Fi g.
3).
The combi nati on fuel fi l ter/water separator pro-
tects the fuel i njecti on pump by hel pi ng to remove
water and contami nants from the fuel . Moi sture col -
l ects at the bottom of the fi l ter/separator i n a pl asti c
bowl .
The fuel fi l ter/water separator assembl y contai ns
the fuel fi l ter, fuel heater el ement, and fuel drai n
val ve.
For i nformati on on the fuel heater, refer to Fuel
Heater i n thi s group.
Refer to the mai ntenance schedul es i n Group 0 i n
thi s manual for the recommended fuel fi l ter repl ace-
ment i nterval s.
For peri odi c drai ni ng of water from the bowl , refer
to Fuel Fi l ter/Water Separator Removal /I nstal l ati on
i n thi s group.
FUEL SHUTDOWN SOLENOID
The fuel shutdown solenoid is controlled and
operated by the MSA.
Fig. 1 Typical Fuel Pressure Test at Injector
Fig. 2 Fuel Tank
14 - 4 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
The fuel shutdown (shut-off) sol enoi d i s used to
el ectri cal l y shut off the di esel fuel suppl y to the hi gh-
pressure fuel i njecti on pump. The sol enoi d i s
mounted to the rear of the i njecti on pump (Fi g. 4).
The sol enoi d control s starti ng and stoppi ng of the
engi ne regardl ess of the posi ti on of the accel erator
pedal . When the i gni ti on (key) swi tch i s OFF, the
sol enoi d i s shut off and fuel fl ow i s not al l owed to the
fuel i njecti on pump. When the key i s pl aced i n the
ON or START posi ti ons, fuel suppl y i s al l owed at the
i njecti on pump.
FUEL INJECTION PUMP
The fuel i njecti on pump i s a mechani cal di stri bu-
tortype, Bosch VP36 seri es (Fi g. 5). A gear on the
end of the i njecti on pump shaft meshes wi th the
dri ve chai n at the front of engi ne. The pump i s
mechani cal l y ti med to the engi ne. The MSA can
make adjustments to the ti mi ng of the i njecti on
pump.
The i njecti on pump contai ns the fuel shutdown
sol enoi d, fuel temperature sensor, control sl eeve sen-
sor, fuel quanti ty actuator and the fuel ti mi ng sol e-
noi d (Fi g. 5).
I n the el ectroni cal l y control l ed i njecti on pump, the
pump pl unger works the same as the pump pl unger
i n a mechani cal l y control l ed i njecti on pump, but the
amount of fuel and the ti me the fuel i s i njected i s
control l ed by the vehi cl es MSA, i nstead of by a
mechani cal governor assembl y. A sol enoi d control l ed
by the MSA i s used i n pl ace of the mechani cal gover-
nor assembl y, and i t moves a control sl eeve i nsi de the
pump that regul ates the amount of fuel bei ng
i njected. There i s no mechani cal connecti on between
the accel erator pedal and the el ectroni cal l y control l ed
i njecti on pump. I nstead, a sensor connected to the
accel erator pedal sends a si gnal to the MSA that rep-
resents the actual posi ti on of the accel erator pedal .
The MSA uses thi s i nput, al ong wi th i nput from
other sensors to move the control sl eeve to del i ver
the appropri ate amount of fuel . Thi s system i s known
as Dri ve-By-Wi re
The actual ti me that the fuel i s del i vered i s very
i mportant to the di esel combusti on process. The MSA
Fig. 3 Fuel Filter/Water Separator Location
Fig. 4 Fuel Shutdown Solenoid and Overflow Valve
Location
Fig. 5 Fuel Injection Pump
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 5
DESCRIPTION AND OPERATION (Continued)
moni tors outputs from the engi ne speed sensor (fl y-
wheel posi ti on i n degrees), and the fuel i njector sen-
sor (mechani cal movement wi thi n the #1 cyl i nder
fuel i njector). Outputs from the Accel erator Pedal
Posi ti on sensor, engi ne speed sensor (engi ne rpm)
and engi ne cool ant temperature sensor are al so used.
The MSA wi l l then compare i ts set val ues to these
outputs to el ectri cal l y adjust the amount of fuel ti m-
i ng (amount of advance) wi thi n the i njecti on pump.
Thi s i s referred to as Cl osed Loop operati on. The
MSA moni tors fuel ti mi ng by compari ng i ts set val ue
to when the i njector #1 opens. I f the val ue i s greater
than a preset val ue a faul t wi l l be set.
Actual el ectri c fuel ti mi ng (amount of advance) i s
accompl i shed by the fuel ti mi ng sol enoi d mounted to
the bottom of the i njecti on pump (Fi g. 5). Fuel ti mi ng
wi l l be adjusted by the MSA, whi ch control s the fuel
ti mi ng sol enoi d.
An overfl ow val ve i s attached i nto the fuel return
l i ne at the rear of the fuel i njecti on pump (Fi g. 4).
Thi s val ve serves two purposes. One i s to ensure that
a certai n amount of resi dual pressure i s mai ntai ned
wi thi n the pump when the engi ne i s swi tched off.
Thi s wi l l prevent the fuel ti mi ng mechani sm wi thi n
the i njecti on pump from returni ng to i ts zero posi -
ti on. The other purpose i s to al l ow excess fuel to be
returned to the fuel tank through the fuel return
l i ne. The pressure val ues wi thi n thi s val ve are preset
and can not be adjusted.
The fuel i njecti on pump suppl i es hi ghpressure
fuel of approxi matel y 45,000 kPa (6526 psi ) to each
i njector i n preci se metered amounts at the correct
ti me.
For mechani cal i njecti on pump ti mi ng, refer to
Fuel I njecti on Pump Ti mi ng i n the Servi ce Proce-
dures secti on of thi s group.
FUEL INJECTORS
Fuel drai n tubes (Fi g. 6) are used to route excess
fuel back to the overfl ow val ve (Fi g. 4) at the rear of
the i njecti on pump. Thi s excess fuel i s then returned
to the fuel tank through the fuel return l i ne.
The i njectors are connected to the fuel i njecti on
pump by the hi gh pressure fuel l i nes. A separate
i njector i s used for each of the four cyl i nders. An
i njector contai ni ng a sensor (Fi g. 7) i s used on the
cyl i nder number one i njector. Thi s i njector i s cal l ed
i nstrumented i njector #1 or needl e movement sensor.
I t i s used to tel l the MSA when the #1 i njectors
i nternal spri ng-l oaded val ve seat has been forced
open by pressuri zed fuel bei ng del i vered to the cyl i n-
der, whi ch i s at the end of i ts compressi on stroke.
When the i nstrumented i njectors val ve seat i s force
open, i t sends a smal l vol tage spi ke pul se to the
MSA. Thi s tel l s the MSA that the engi ne i s at TDC
on the number one cyl i nder. I t i s not used wi th the
other three i njectors.
Fuel enters the i njector at the fuel i nl et (top of
i njector) and i s routed to the needl e val ve bore. When
fuel pressure ri ses to approxi matel y 15,00015,800
kPa (21752291 psi ), the needl e val ve spri ng tensi on
i s overcome. The needl e val ve ri ses and fuel fl ows
through the spray hol es i n the nozzl e ti p i nto the
combusti on chamber. The pressure requi red to l i ft
the needl e val ve i s the i njector openi ng pressure set-
ti ng. Thi s i s referred to as the pop-off pressure set-
ti ng.
Fuel pressure i n the i njector ci rcui t decreases after
i njecti on. The i njector needl e val ve i s i mmedi atel y
cl osed by the needl e val ve spri ng and fuel fl ow i nto
Fig. 6 Fuel Injectors and Drain Tubes
Fig. 7 Fuel Injector Sensor
14 - 6 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
the combusti on chamber i s stopped. Exhaust gases
are prevented from enteri ng the i njector nozzl e by
the needl e val ve.
A copper washer (gasket) i s used at the base of
each i njector (Fi g. 7) to prevent combusti on gases
from escapi ng.
Fuel i njector fi ri ng sequence i s 1342.
FUEL TUBES/LINES/HOSES AND CLAMPS LOW-
PRESSURE TYPE
Al so refer to the proceedi ng secti on on Qui ckCon-
nect Fi tti ngs.
I nspect al l hose connecti ons such as cl amps, cou-
pl i ngs and fi tti ngs to make sure they are secure and
l eaks are not present. The component shoul d be
repl aced i mmedi atel y i f there i s any evi dence of deg-
radati on that coul d resul t i n fai l ure.
Never attempt to repai r a pl asti c fuel l i ne/tube or a
qui ckconnect fi tti ng. Repl ace compl ete l i ne/tube as
necessary.
Avoi d contact of any fuel tubes/hoses wi th other
vehi cl e components that coul d cause abrasi ons or
scuffi ng. Be sure that the fuel l i nes/tubes are prop-
erl y routed to prevent pi nchi ng and to avoi d heat
sources.
The l i nes/tubes/hoses are of a speci al constructi on.
I f i t i s necessary to repl ace these l i nes/tubes/hoses,
use onl y ori gi nal equi pment type.
The hose cl amps used to secure the rubber hoses
are of a speci al rol l ed edge constructi on. Thi s con-
structi on i s used to prevent the edge of the cl amp
from cutti ng i nto the hose. Onl y these rol l ed edge
type cl amps may be used i n thi s system. Al l other
types of cl amps may cut i nto the hoses and cause
fuel l eaks.
Where a rubber hose i s joi ned to a metal tube
(staked), do not attempt to repai r. Repl ace enti re
l i ne/tube assembl y.
Use new ori gi nal equi pment type hose cl amps.
Ti ghten hose cl amps to 2 Nm (20 i n. l bs.) torque.
QUICK-CONNECT FITTINGS LOW PRESSURE
TYPE
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type or a pl asti c retai ner
ri ng type (Fi g. 8). Refer to Qui ck-Connect Fi tti ngs i n
the Removal /I nstal l ati on secti on for more i nforma-
ti on.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
HIGH-PRESSURE FUEL LINES
CAUTION: The highpressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
Hi ghpressure fuel l i nes del i ver fuel under pres-
sure of up to approxi matel y 45,000 kPa (6526 PSI )
from the i njecti on pump to the fuel i njectors. The
l i nes expand and contract from the hi ghpressure
fuel pul ses generated duri ng the i njecti on process. Al l
hi ghpressure fuel l i nes are of the same l ength and
i nsi de di ameter. Correct hi ghpressure fuel l i ne
usage and i nstal l ati on i s cri ti cal to smooth engi ne
operati on.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGHPRESSURE FUEL LEAKS.
INSPECT FOR HIGHPRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL DRAIN TUBES
These rubber tubes are l owpressure type.
Some excess fuel i s conti nual l y vented from the
fuel i njecti on pump. Duri ng i njecti on, a smal l amount
of fuel fl ows past the i njector nozzl e and i s not
i njected i nto the combusti on chamber. Thi s fuel
drai ns i nto the fuel drai n tubes (Fi g. 9) and back to
the tee banjo fi tti ng, whi ch i s connected to the same
Fig. 8 Plastic Retainer Ring-Type Fitting
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 7
DESCRIPTION AND OPERATION (Continued)
l i ne as the overfl ow val ve, whi ch al l ows a vari abl e
quanti ty to return to the fuel tank. The overfl ow
val ve i s cal i brated to open at a preset pressure.
Excess fuel not requi red by the pump to mai ntai n the
mi ni mum pump cavi ty pressure i s then returned
through the overfl ow val ve and on to the fuel tank
through the fuel return l i ne.
FUEL HEATER
The fuel heater i s used to prevent di esel fuel from
waxi ng duri ng col d weather operati on. The fuel
heater i s l ocated i n the bottom pl asti c bowl of the
fuel fi l ter/water separator (Fi g. 10).
The el ement i nsi de the heater assembl y i s made of
a Posi ti ve Temperature Coeffi ci ent (PTC) materi al ,
and has power appl i ed to i t by the fuel heater rel ay
anyti me the i gni ti on key i s i n the on posi ti on. PTC
materi al has a hi gh resi stance to current fl ow when
i ts temperature temperature i s hi gh, whi ch means
that i t wi l l not generate heat when the temperature
i s above a certai n val ue. When the temperature i s
bel ow 7C (45 F), the resi stance of the PTC el ement
i s l owered, and al l ows current to fl ow through the
fuel heater el ement warmi ng the fuel . When the tem-
perature i s above 29C (85 F), the PTC el ements
resi stance ri ses, and current fl ow through the heater
el ement stops.
Vol tage to operate the fuel heater i s suppl i ed from
the i gni ti on (key) swi tch and through the fuel heater
rel ay. Refer to the fol l owi ng Fuel Heater Rel ay for
addi ti onal i nformati on. The fuel heater and fuel
heater relay are not controlled by the Power-
train Control Module (PCM).
Current draw for the heater el ement i s 150 watts
at 14 vol ts (DC).
FUEL HEATER RELAY
Vol tage to operate the fuel heater i s suppl i ed from
the i gni ti on (key) swi tch through the fuel heater
rel ay. The PCM or MSA is not used to control
this relay.
The fuel heater rel ay i s l ocated i n the PDC. The
PDC i s l ocated next to the battery i n the engi ne com-
partment (Fi g. 11). For the l ocati on of the rel ay
wi thi n the PDC, refer to l abel on PDC cover.
Fig. 9 Fuel Drain Tubes
Fig. 10 Fuel Heater Temperature Sensor and
Element Location
Fig. 11 Relay Location
14 - 8 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and I ntake
Mani fol d for i nformati on.
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Thi s secti on of the group wi l l cover a general di ag-
nosi s of di esel engi ne fuel system components.
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
The PCM and MSA must be tested wi th the
DRBI I I scan tool . The DRBI I I shoul d be the fi rst
step i n any di agnosi s of engi ne performance com-
pl ai nts. Refer to the 1997 ZJ/ZG 2.5L Di esel Power-
trai n Di agnosti c Procedures manual for di agnosi s
and testi ng of the di esel engi ne control system.
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected, or i ncor-
rectl y routed wi res and hoses shoul d be made before
attempti ng to di agnose or servi ce the di esel fuel
i njecti on system. A vi sual check wi l l hel p fi nd these
condi ti ons. I t al so saves unnecessary test and di ag-
nosti c ti me. A thorough vi sual i nspecti on of the fuel
i njecti on system i ncl udes the fol l owi ng checks:
(1) Be sure that the battery connecti ons are ti ght
and not corroded.
(2) Be sure that the 60 way connector i s ful l y
engaged wi th the PCM (Fi g. 12).
(3) Be sure that the 68 way connector i s ful l y
engaged wi th the MSA (Fi g. 13)
(4) Veri fy that the el ectri cal connecti ons for the
ASD rel ay are cl ean and free of corrosi on. Thi s rel ay
i s l ocated i n the PDC. For the l ocati on of the rel ay
wi thi n the PDC, refer to l abel on PDC cover.
(5) Veri fy that the el ectri cal connecti ons for the
fuel heater rel ay are cl ean and free of corrosi on. Thi s
rel ay i s l ocated i n the PDC. For the l ocati on of the
rel ay wi thi n the PDC, refer to l abel on PDC cover.
(6) Be sure the el ectri cal connectors at the ends of
the gl ow pl ugs (Fi g. 14) are ti ght and free of corro-
si on.
Fig. 12 PCM LocationTypical
Fig. 13 MSA LocationTypical
Fig. 14 Glow Plug Connector
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 9
DESCRIPTION AND OPERATION (Continued)
(7) Be sure that the el ectri cal connecti ons at the
gl ow pl ug rel ay are ti ght and not corroded. The gl ow
pl ug rel ay i s l ocated i n the engi ne compartment on
the l efti nner fender (Fi g. 15).
(8) I nspect the starter motor and starter sol enoi d
connecti ons for ti ghtness and corrosi on.
(9) Veri fy that the Fuel I njecti on Pump el ectri cal
connector i s fi rml y connected. I nspect the connector
for corrosi on or damaged wi res. The sol enoi d i s
mounted to the rear of the i njecti on pump (Fi g. 16).
(10) Veri fy that the fuel heater el ectri cal connector
i s fi rml y attached to the fi l ter bowl at the bottom of
the fuel fi l ter/water separator. I nspect the connector
for corrosi on or damaged wi res.
(11) Veri fy that the el ectri cal pi gtai l connector
(sensor connector) (Fi g. 17) for the fuel i njector sen-
sor i s fi rml y connected to the engi ne wi ri ng harness.
I nspect the connector for corrosi on or damaged wi res.
Thi s sensor i s used on the #1 cyl i nder i njector onl y.
(12) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes or a col l apsed or pl ugged
muffl er.
(13) Veri fy that the harness connector i s fi rml y
connected to the vehi cl e speed sensor (Fi g. 18) or
(Fi g. 19).
Fig. 15 Glow Plug Relay Location
Fig. 16 Fuel Shutdown Solenoid Location
Fig. 17 Fuel Injector Sensor
Fig. 18 Vehicle Speed Sensor2 Wheel Drive
14 - 10 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
(14) Veri fy turbocharger wastegate operati on.
Refer to Group 11, Exhaust System and I ntake Man-
i fol d Group for i nformati on.
(15) Veri fy that the harness connector i s fi rml y
connected to the engi ne cool ant temperature sensor.
The sensor i s l ocated on the si de of cyl i nder head
near the rear of fuel i njecti on pump (Fi g. 20).
(16) Check for ai r i n the fuel system. Refer to the
Ai r Bl eed Procedure.
(17) I nspect al l fuel suppl y and return l i nes for
si gns of l eakage.
(18) Be sure that the ground connecti ons are ti ght
and free of corrosi on. Refer to Group 8, Wi ri ng for
l ocati ons of ground connecti ons.
(19) I nspect the ai r cl eaner el ement (fi l ter) for
restri cti ons.
(20) Be sure that the turbocharger output hose i s
properl y connected to the charge ai r cool er (i nter-
cool er) i nl et tube. Veri fy that the charge ai r cool er
output hose i s properl y connected to the cool er and
the i ntake mani fol d. Refer to Group 11, Exhaust Sys-
tem and I ntake Mani fol d for i nformati on.
(21) Be sure that the vacuum hoses to the vacuum
pump are connected and not l eaki ng. There are two
pumps. One i s l ocated on the front of engi ne (i nter-
nal ) and i s dri ven from the crankshaft gear (Fi g. 22).
The other i s mounted to the front of the generator
(Fi g. 21). Di sconnect the hose and check for mi ni -
mum vacuum from the pump. Refer to Group 5,
Brake System for speci fi cati ons and procedures.
(22) Be sure that the accessory dri ve bel t i s not
damaged or sl i ppi ng.
Fig. 19 Vehicle Speed Sensor4 Wheel Drive
Fig. 20 Engine Coolant Temperature Sensor Location
Fig. 21 Vacuum Pump at Generator
Fig. 22 Vaccum Pump at Front of Engine
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 11
DIAGNOSIS AND TESTING (Continued)
(23) Veri fy there i s a good connecti on at the engi ne
speed sensor. Refer to the Fuel I njecti on System i n
thi s secti on for l ocati on of the engi ne speed sensor
l ocati on.
(24) Veri fy there i s a good connecti on at the Mass
Ai r Fl ow Sensor, whi ch i s a part of the ai r i ntake
assembl y.
AIR IN FUEL SYSTEM
Ai r wi l l enter the fuel system whenever the fuel
suppl y l i nes, fuel fi l ter/water separator, fuel fi l ter
bowl , i njecti on pump, hi ghpressure l i nes or i njectors
are removed or di sconnected. Ai r wi l l al so enter the
fuel system whenever the fuel tank has been run
empty.
Ai r trapped i n the fuel system can resul t i n hard
starti ng, a rough runni ng engi ne, engi ne mi sfi re, l ow
power, excessi ve smoke and fuel knock. After servi ce
i s performed, ai r must be bl ed from the system
before starti ng the engi ne.
I nspect the fuel system from the fuel tank to the
i njectors for l oose connecti ons. Leaki ng fuel i s an
i ndi cator of l oose connecti ons or defecti ve seal s. Ai r
can al so enter the fuel system between the fuel tank
and the i njecti on pump. I nspect the fuel tank and
fuel l i nes for damage that mi ght al l ow ai r i nto the
system.
For ai r bl eedi ng, refer to Ai r Bl eed Procedure i n
the Servi ce Procedures secti on of thi s group.
FUEL HEATER RELAY TEST
The fuel heater rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC). Refer to Rel aysOperati on/
Testi ng i n Fuel I ngecti on System secti on of thi s
group for test procedures.
FUEL INJECTOR TEST
The fuel i njecti on nozzel s, l ocated on the engi ne
cyl i nder head, spray fuel under hi gh pressure i nto
the i ndi vi dual combusti on chambers. Pressuri zed
fuel , del i vered by the fuel i njecti on pump, unseats a
spri ng-l oaded needl e val ve i nsi de the i njector, and
the fuel i s atomi zed as i t escapes through the i njector
openi ng i nto the engi nes combusti on chamber. I f the
fuel i njector does not operate properl y, the engi ne
may mi sfi re, or cause other dri veabi l i ty probl ems.
A l eak i n the i njecti on pumptoi njector hi ghpres-
sure fuel l i ne can cause many of the same symptoms
as a mal functi oni ng i njector. I nspect for a l eak i n the
hi ghpressure l i nes before checki ng for a mal func-
ti oni ng fuel i njector.
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF UP TO APPROXIMATELY
45,000 KPA (6526 PSI) TO EACH INDIVIDUAL INJEC-
TOR THROUGH THE HIGHPRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING. AVOID CONTACT WITH FUEL
SPRAY WHEN BLEEDING HIGHPRESSURE FUEL
LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
To determi ne whi ch fuel i njector i s mal functi oni ng,
run the engi ne and l oosen the hi ghpressure fuel l i ne
nut at the i njector (Fi g. 23). Li sten for a change i n
engi ne speed. I f engi ne speed drops, the i njector was
operati ng normal l y. I f engi ne speed remai ns the
same, the i njector may be mal functi oni ng. After test-
i ng, ti ghten the l i ne nut to 30 Nm (22 ft. l bs.)
torque. Test al l i njectors i n the same manner one at
a ti me.
Once an i njector has been found to be mal functi on-
i ng, remove i t from the engi ne and test i t. Refer to
the Removal /I nstal l ati on secti on of thi s group for pro-
cedures.
After the i njector has been removed, i nstal l i t to a
benchmount i njector tester. Refer to operati ng
i nstructi ons suppl i ed wi th tester for procedures.
The openi ng pressure or pop pressure shoul d be
15,00015,800 kPa (21752291 psi ). I f the fuel i njec-
tor needl e val ve i s openi ng (poppi ng) to earl y or to
l ate, repl ace the i njector.
Fig. 23 Typical Inspection of Fuel Injector
14 - 12 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
FUEL INJECTOR SENSOR TEST
The fuel i njector sensor i s used onl y on the fuel
i njector for the number1 cyl i nder (Fi g. 24). I t i s not
used on the i njectors for cyl i nders number 2, 3, or 4.
To test the sensor, unpl ug the sensor connector
(Fi g. 24) from the engi ne wi ri ng harness. Check
resi stance across termi nal s. Resi stance shoul d be 110
ohms 10 ohms at 20C (68F). Repl ace sensor i f
speci fi cati on cannot be met.
FUEL INJECTION PUMP TEST
The injection pump is not to be serviced or
the warranty may be voided. If the injection
pump requires service, the complete assembly
must be replaced.
I ncorrect i njecti on pump ti mi ng (mechani cal or
el ectri cal ) can cause poor performance, excessi ve
smoke and emi ssi ons and poor fuel economy.
A defecti ve fuel i njecti on pump, defecti ve fuel ti m-
i ng sol enoi d or mi sadjusted mechani cal pump ti mi ng
can cause starti ng probl ems or prevent the engi ne
from revvi ng up. I t can al so cause:
Engi ne surge at i dl e
Rough i dl e (warm engi ne)
Low power
Excessi ve fuel consumpti on
Poor performance
Low power
Bl ack smoke from the exhaust
Bl ue or whi te fog l i ke exhaust
I ncorrect i dl e or maxi mum speed
The el ectroni cal l y control l ed fuel pump has no
mechani cal governor l i ke ol der mechani cal l y con-
trol l ed fuel pumps. Do not remove the top cover of
the fuel pump, or the screws fasteni ng the wi ri ng
pi gtai l to the si de of the pump. The warranty of
the injection pump and the engine may be void
if those seals have been removed or tampered
with.
FUEL SUPPLY RESTRICTIONS
LOWPRESSURE LINES
Restri cted or Pl ugged suppl y l i nes or fuel fi l ter can
cause a ti mi ng faul t that wi l l cause the PCM to oper-
ate the engi ne i n a Li mp Home mode. See the
i ntroducti on of the Fuel I njecti on System i n thi s
group for more i nformati on on the Li mp Home mode.
Fuel suppl y l i ne restri cti ons can cause starti ng prob-
l ems and prevent the engi ne from revvi ng up. The
starti ng probl ems i ncl ude; l ow power and bl ue or
whi te fog l i ke exhaust. Test al l fuel suppl y l i nes for
restri cti ons or bl ockage. Fl ush or repl ace as neces-
sary. Bl eed the fuel system of ai r once a fuel suppl y
l i ne has been repl aced. Refer to the Ai r Bl eed Proce-
dure secti on of thi s group for procedures.
HIGHPRESSURE LINES
Restri cted (ki nked or bent) hi ghpressure l i nes can
cause starti ng probl ems, poor engi ne performance
and bl ack smoke from exhaust.
Exami ne al l hi ghpressure l i nes for any damage.
Each radi us on each hi ghpressure l i ne must be
smooth and free of any bends or ki nks.
Repl ace damaged, restri cted or l eaki ng hi ghpres-
sure fuel l i nes wi th the correct repl acement l i ne.
CAUTION: The highpressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
FUEL SHUTDOWN SOLENOID TEST
Refer to 1997 ZJ/ZG 2.5L Di esel Powertrai n Di ag-
nosti c Manual for the Fuel Shutdown Sol enoi d test.
HIGH-PRESSURE FUEL LINE LEAK TEST
Hi ghpressure fuel l i ne l eaks can cause starti ng
probl ems and poor engi ne performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 45,000 KPA (6526 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGHPRES-
SURE FUEL LEAKS. DO NOT GET YOUR HAND, OR
ANY PART OF YOUR BODY NEAR A SUSPECTED
LEAK. INSPECT FOR HIGHPRESSURE FUEL
LEAKS WITH A SHEET OF CARDBOARD. HIGH
FUEL INJECTION PRESSURE CAN CAUSE PER-
SONAL INJURY IF CONTACT IS MADE WITH THE
SKIN.
Fig. 24 Fuel Injector Sensor Location
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 13
DIAGNOSIS AND TESTING (Continued)
Start the engi ne. Move the cardboard over the
hi ghpressure fuel l i nes and check for fuel spray onto
the cardboard (Fi g. 25). I f a hi ghpressure l i ne con-
necti on i s l eaki ng, bl eed the system and ti ghten the
connecti on. Refer to the Ai r Bl eed Procedure i n thi s
group for procedures. Repl ace damaged, restri cted or
l eaki ng hi ghpressure fuel l i nes wi th the correct
repl acement l i ne.
CAUTION: The highpressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and I ntake
Mani fol d for i nformati on.
SERVICE PROCEDURES
AIR BLEED PROCEDURES
AIR BLEEDING AT FUEL FILTER
A certai n amount of ai r may become trapped i n the
fuel system when fuel system components are ser-
vi ced or repl aced. Bl eed the system as needed after
fuel system servi ce accordi ng to the fol l owi ng proce-
dures.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Some ai r enters the fuel system when the fuel fi l -
ter or i njecti on pump suppl y l i ne i s changed. Thi s
smal l amount of ai r i s vented automati cal l y from the
i njecti on pump through the fuel drai n mani fol d tubes
i f the fi l ter was changed accordi ng to i nstructi ons.
Ensure the bowl of the fuel fi l ter/water separator i s
ful l of fuel
I t may be necessary to manual l y bl eed the system
i f:
The bowl of the fuel fi l ter/water separator i s not
parti al l y fi l l ed before i nstal l ati on of a new fi l ter
The i njecti on pump i s repl aced
Hi ghpressure fuel l i ne connecti ons are l oosened
or l i nes repl aced
I ni ti al engi ne startup or startup after an
extended peri od of no engi ne operati on
Runni ng fuel tank empty
FUEL INJ ECTION PUMP BLEEDING
(1) I f the fuel i njecti on pump has been repl aced,
ai r shoul d be bl ed at the overfl ow val ve before
attempti ng to start engi ne.
(a) Loosen the overfl ow val ve (Fi g. 26) at the
rear of the i njecti on pump.
(b) Pl ace a towel bel ow the val ve.
Fig. 25 Typical Test for Leaks with Cardboard
Fig. 26 Overflow Valve
14 - 14 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
WARNING: WHEN CRANKING THE ENGINE TO
BLEED AIR FROM THE INJECTION PUMP, THE
ENGINE MAY START. PLACE THE TRANSMISSION
IN NEUTRAL OR PARK AND SET PARKING BRAKE
BEFORE ENGAGING THE STARTER MOTOR.
CAUTION: Do not engage the starter motor for
more than 30 seconds at a time. Allow 2 minutes
between cranking intervals.
(2) Crank the engi ne for 30 seconds at a ti me to
al l ow ai r trapped i n the i njecti on pump to vent out
the fuel i njector drai n tubes. Conti nue thi s procedure
unti l the engi ne starts. Observe the previ ous WARN-
I NG and CAUTI ON.
(3) Ti ghten overfl ow val ve.
HIGHPRESSURE FUEL LINE BLEEDING
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF APPROXIMATELY 59,000 KPA
(8,557 PSI) TO EACH INDIVIDUAL INJECTOR
THROUGH THE HIGHPRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING AND AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGHPRESSURE
FUEL LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Bl eed ai r from one i njector at ti me.
(1) Loosen the hi ghpressure fuel l i ne fi tti ng at
the i njector (Fi g. 27).
(2) Crank the engi ne unti l al l ai r has been bl ed
from the l i ne. Do not operate the starter motor
for longer than 30 seconds. Wait 2 minutes
between cranking intervals.
(3) Start the engi ne and bl eed one i njector at a
ti me unti l the engi ne runs smoothl y.
FUEL INJECTION PUMP TIMING
Refer to Removal /I nstal l ati on and Adjusti ng Fuel
Pump Ti mi ng i n thi s Group.
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
REMOVAL
(1) Di sconnect el ectri cal connector.
(2) Remove accel erator pedal mounti ng bracket
nuts. Remove accel erator pedal assembl y.
Fig. 27 Bleeding HighPressure Fuel LineTypical
Fig. 28 Accelerator Pedal Mounting-Typical
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 15
SERVICE PROCEDURES (Continued)
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
5 Nm (46 i n. l bs.) torque.
(2) Connect el ectri cal connector.
(3) Before starti ng the engi ne, operate the accel er-
ator pedal to check for any bi ndi ng.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove hose cl amp at Mass Ai r Fl ow Sensor.
(2) Remove hose from Mass Ai r Fl ow Sensor.
(3) Loosen 2 cl amps hol di ng ai r cl eaner housi ng
hal ves together.
(4) Remove l eft si de of ai r cl eaner housi ng.
(5) Remove el ement from ai r cl eaner housi ng.
INSTALLATION
(1) I nstal l a new el ement i n housi ng.
(2) Posi ti on l eft si de of housi ng.
(3) Snap cl amps i nto pl ace.
(4) I nstal l hoses and cl amps.
FUEL DRAIN TUBES
The fuel drai n tubes (Fi g. 29) are l owpressure
type.
Pul l each tube from the i njector for removal . Push
on for i nstal l ati on. Cl amps are not requi red for these
tubes.
FUEL FILTER/WATER SEPARATOR
The fuel fi l ter/water separator i s l ocated i n the
engi ne compartment on the ri ght si de near the shock
tower. (Fi g. 30).
The fuel fi l ter/water separator assembl y contai ns
the fuel fi l ter, fuel heater el ement, and fuel drai n
val ve (Fi g. 30).
DRAINING WATER FROM FILTER BOWL
Moi sture (water) col l ects at the bottom of the fi l ter/
separator i n a pl asti c bowl . Water enteri ng the fuel
i njecti on pump can cause seri ous damage to the
pump. Note that the bulb will be illuminated for
approximately 2 seconds each time the key is
initially placed in the ON position. This is done
for a bulb check.
WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
(1) The bottom of the fi l ter/separator bowl i s
equi pped wi th a drai n val ve (Fi g. 30). The drai n
val ve i s equi pped wi th a fi tti ng. Attach a pi ece of
rubber hose to thi s fi tti ng. Thi s hose i s to be used as
a drai n hose.
(2) Pl ace a drai n pan under the drai n hose.
(3) Wi th the engi ne not runni ng, open the drai n
val ve (unscrewdrai n val ve has ri ght hand threads)
from the fi l ter/separator bowl . To gai n access to thi s
fi tti ng, the two fi l tertomounti ng bracket nuts (Fi g.
30) may have to be l oosened a few turns.
Fig. 29 Fuel Drain Tubes
Fig. 30 Fuel Filter/Water Separator Location
14 - 16 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(4) Hol d the drai n open unti l cl ean fuel exi ts the
drai n.
(5) After drai ni ng, cl ose drai n val ve.
(6) Remove rubber drai n hose.
(7) Di spose of mi xture i n drai n pan accordi ng to
appl i cabl e l ocal or federal regul ati ons.
FUEL FILTER REMOVAL
(1) Drai n al l fuel and/or water from fuel fi l ter/wa-
ter separator assembl y. Refer to the previ ous Drai n-
i ng Water From Fi l ter Bowl .
(2) Unpl ug the el ectri cal connectors at bottom of
pl asti c bowl .
(3) Remove pl asti c bowl from bottom of fuel fi l ter
(unscrews).
(4) Remove fuel fi l ter from bottom of fi l ter base
(unscrews).
FUEL FILTER INSTALLATION
(1) Cl ean bottom of fuel fi l ter base.
(2) Appl y cl ean di esel fuel to new fuel fi l ter gasket.
(3) I nstal l and ti ghten fi l ter to fi l ter base. The bev-
el ed part of the rubber gasket shoul d be faci ng up
towards the fi l ter base.
(4) Cl ean the i nsi de of bowl wi th a soap and water
mi xture before i nstal l ati on. Careful l y cl ean any resi -
due between the two metal probes at the top of the
wateri nfuel sensor. Do not use chemi cal cl eaners
as damage to the pl asti c bowl may resul t.
(5) Pour di esel fuel i nto the pl asti c bowl before
i nstal l i ng bowl to bottom of fuel fi l ter. Do thi s to hel p
prevent ai r from enteri ng fuel i njecti on pump whi l e
attempti ng to starti ng engi ne.
(6) I nstal l fi l ter bowl to bottom of fi l ter.
(7) I nstal l the el ectri cal connectors at bottom of
bowl .
(8) Ti ghten the fi l tertomounti ng bracket nuts
(Fi g. 30) to 28 Nm (250 i n. l bs.) torque.
FUEL HEATER
I f the fuel heater el ement needs repl acement, the
pl asti c fi l ter bowl assembl y must be repl aced. Refer
to Fuel Fi l ter/Water Separator for i nformati on.
FUEL HEATER RELAY
The fuel heater rel ay i s l ocated i n the PDC. For
the l ocati on of the rel ay wi thi n the PDC (Fi g. 31),
refer to l abel on PDC cover.
FUEL LEVEL SENSOR
The fuel l evel sensor i s l ocated on the si de of the
fuel pump modul e. (Fi g. 32)
Fig. 31 Power Distribution Center (PDC) Location
Fig. 32 Fuel Level Sensor
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 17
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 33) to remove send-
i ng uni t from pump modul e.
FUEL INJECTION PUMP
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Thoroughl y cl ean the area around the i njecti on
pump and fuel l i nes of al l di rt, grease and other con-
tami nants. Due to the close internal tolerances
of the injection pump, this step must be per-
formed before removing pump.
(3) Remove the engi ne accessory dri ve bel t. Refer
to Group 7, Cool i ng System for procedures.
(4) Remove the generator assembl y.
(5) Remove the rubber fuel return and suppl y
hoses from metal l i nes at pump (Fi g. 34).
(6) Remove the el ectri cal connector at engi ne cool -
ant temperature sensor (Fi g. 35).
(7) Di sconnect the Fuel I njecti on Pump el ectri cal
connector at fuel pump. (Fi g. 34).
(8) Di sconnect the mai n engi ne wi ri ng harness
from the gl ow pl ugs.
(9) Di sconnect the four hi ghpressure fuel l i nes
from the fuel i njecti on pump. Al so di sconnect fuel
l i nes at the fuel i njectors. For procedures, refer to
Hi ghPressure Fuel Li nes i n thi s group. Pl ace a rag
beneath the fi tti ngs to catch excess fuel .
(10) Remove pl ug from ti mi ng gear cover.
(11) The Top Dead Center (TDC) compressi on fi r-
i ng stroke must be determi ned as fol l ows:
(a) Remove the val ve cover, refer to Group 9,
Val ve Cover Removal /I nstal l ati on.
(b) Remove the ri ght front ti re and spl ash
shi el d. Usi ng a socket attached to the end of crank-
shaft, rotate the engi ne (countercl ockwi se as
vi ewed from front).
(c) Rotate the engi ne unti l cyl i nder #4 rockers
are i n between movement.
Fig. 33 Fuel Level Sensor Release Tab
Fig. 34 Overflow Valve and Fuel Shutdown Solenoid
Fig. 35 Engine Coolant Temperature Sensor
14 - 18 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(d) Remove rocker arm assembl y.
(e) Remove val ve spri ng and keepers. CAU-
TION: When the piston is at TDC there is only
2 mm (.080 thousand) clearance between the
valve and piston.
(f) Let the val ve set on top of pi ston. I nstal l a
di al i ndi cator to the top of the val ve stem.
(g) Rotate engi ne back and forth to fi nd the TDC
posi ti on wi th the i ndi cator on the val ve stem. Mark
the damper and ti mi ng cover for TDC.
NOTE: On later model 1997 engines, a hole in the
bottom of the clutch housing can be lined up with a
hole in the flywheel, allowing the engine to be held
at TDC with a special alignment tool, part # VM1035.
(12) Remove i njecti on pump dri ve gear nut (Fi g.
36) and washer. CAUTION: Be very careful not to
drop the washer into the timing gear cover.
(13) A speci al 3pi ece gear removal tool set
VM.1003 (Fi g. 37) must be used to remove the i njec-
ti on pump dri ve gear from the pump shaft.
(a) Thread the adapter (Fi g. 38) i nto the ti mi ng
cover.
(b) Thread the gear pul l er i nto the i njecti on
pump dri ve gear (Fi g. 38). Thi s tool i s al so used to
hol d the gear i n synchroni zati on duri ng pump
removal .
(c) Remove the three i njecti on pumptogear
cover mounti ng nuts (Fi g. 39). CAUTION: This
step must be done to prevent breakage of the
three injection pump mounting flanges while
gear is being removed.
(d) I nstal l the dri ve bol t i nto the gear pul l er
(Fi g. 38). Ti ghten the dri ve bol t to press (remove)
the dri ve gear from i njecti on pump shaft whi l e
dri vi ng i njecti on pump rearward from ti mi ng gear
cover mounti ng studs.
(14) Remove pump from engi ne. Do not rotate
engine while gear puller is installed. Engine
damage will occur.
INSTALLATION/ADJ USTING PUMP TIMING
(1) Cl ean the mati ng surfaces of i njecti on pump
and ti mi ng gear cover.
(2) I nstal l a new i njecti on pumptoti mi ng gear
cover gasket.
Fig. 36 Removing Pump Drive Gear Nut
Fig. 37 Pump Gear Tools
Fig. 38 Installing Pump Drive Gear Removal Tools
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 19
REMOVAL AND INSTALLATION (Continued)
(3) Remove the gear removi ng bol t (dri ve bol t)
from gear pul l er. CAUTION: Do not remove the
special gear puller or timing cover adapter
tools from timing cover at this time. Gear mis-
alignment will result.
(4) Pl ace the key way on the pump shaft to the 11
ocl ock posi ti on as vi ewed from the front of pump.
I nstal l the pump i nto the rear of ti mi ng gear cover
whi l e al i gni ng key way on pump shaft i nto pump
gear.
(5) I nstal l and snug the 3 i njecti on pump mount-
i ng nuts. Thi s i s not the fi nal ti ghteni ng sequence.
(6) Remove the speci al gear pul l er and adapter
tool s from ti mi ng gear cover.
(7) I nstal l the i njecti on pump dri ve gear nut and
washer. Ti ghten nut to 88 Nm (65 ft. l bs.) torque.
(8) Remove access pl ug and pl ug washer at rear of
pump (Fi g. 40). Thread speci al di al i ndi cator adapter
tool VM.1011 (Fi g. 41) i nto thi s openi ng. Hand
ti ghten onl y.
(9) Attach speci al di al i ndi cator tool VM.1013 i nto
the adapter tool (Fi g. 41).
(10) Usi ng a socket attached to the end of crank-
shaft, rotate the engi ne (countercl ockwi se as
vi ewed from front) unti l thedi al i ndi cator stops mov-
i ng. Thi s rotati on i s about 20 to 30.
(11) Set the di al i ndi cator to 0 mm. Be sure the ti p
of di al i ndi cator i s touchi ng the ti p i nsi de the adapter
tool .
(12) Very sl owl y rotate the crankshaft cl ockwi se
unti l movement on di al i ndi cator needl e has stopped.
Do not rotate crankshaft after needle move-
ment has stopped. Engine should be at TDC at
this point
(13) Check the TDC di al i ndi cator for TDC.
(14) Gauge readi ng shoul d be at 0.60 mm. I f not,
the pump must be rotated for adjustment:
(a) Loosen the three i njecti on pump mounti ng
nuts at the mounti ng fl anges. These fl anges are
equi pped wi th sl otted hol es. The sl otted hol es are
used to rotate and posi ti on the i njecti on pump for
fuel ti mi ng. Loosen the three nuts just enough to
rotate the pump.
(b) Rotate the pump clockwise (as vi ewed from
front) unti l .60 mm i s i ndi cated on the di al i ndi ca-
tor gauge.
(c) Ti ghten the three pump mounti ng nuts to 30
Nm (22 ft. l bs.) torque.
Fig. 39 Injection Pump Mounting Nuts
Fig. 40 Access Plug at Rear of Pump
Fig. 41 Installing Dial Indicator and Special Adapter
Tools
14 - 20 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(d) Recheck the di al i ndi cator after ti ghteni ng
the pump mounti ng nuts. Gauge shoul d sti l l be
readi ng 0.60 mm. Loosen pump mounti ng nuts and
readjust i f necessary.
(15) Remove di al i ndi cator and adapter tool s.
(16) I nstal l access pl ug and washer to rear of
i njecti on pump.
(17) I nstal l pl ug at ti mi ng gear cover.
(18) Remove di al i ndi cator from val ve stem.
(19) I nstal l val ve spri ng and keepers.
(20) I nstal l rocker arm assembl y and ti ghten nuts.
(21) I nstal l and connect the four hi ghpressure
fuel l i nes to the fuel i njecti on pump. Al so connect
fuel l i nes at the fuel i njectors. For procedures, refer
to Hi ghPressure Fuel Li nes i n thi s group.
(22) I nstal l el ectri cal connector at engi ne cool ant
temperature sensor.
(23) Connect el ectri cal connector at fuel shutdown
sol enoi d.
(24) Connect the mai n engi ne wi ri ng harness to
the gl ow pl ugs.
(25) Connect the fuel ti mi ng sol enoi d pi gtai l har-
ness to the engi ne wi ri ng harness.
(26) Connect the overfl ow val ve/banjo fi tti ng (fuel
return l i ne assembl y). Repl ace copper gaskets before
i nstal l i ng.
(27) Connect the rubber fuel return and suppl y
hoses to metal l i nes at pump. Ti ghten hose cl amps to
2 Nm (20 i n. l bs.) torque.
(28) I nstal l generator assembl y.
(29) I nstal l engi ne accessory dri ve bel t. Refer to
Group 7, Cool i ng System for procedures.
(30) I nstal l negati ve battery cabl e to battery.
(31) Start the engi ne and bri ng to normal operat-
i ng temperature.
(32) Check for fuel l eaks.
FUEL INJECTORS
Four fuel i njectors are used on each engi ne. Of
these four, two di fferent types are used. The fuel
i njector used on cyl i nder number one i s equi pped
wi th a fuel i njector sensor (Fi g. 42). The other three
fuel i njectors are i denti cal . Do not place the fuel
injector equipped with the fuel injector sensor
into any other location except the cylinder
number one position.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Thoroughl y cl ean the area around the i njector
wi th compressed ai r.
(3) Remove the fuel drai n hoses (tubes) at each
i njector (Fi g. 43) bei ng servi ced. Each of these hoses
i s sl i pfi t to the fi tti ng on i njector.
(4) Remove the hi ghpressure fuel l i ne at i njector
bei ng removed. Refer to Hi ghPressure Fuel Li nes i n
thi s group for procedures.
(5) Remove the i njector usi ng speci al socket tool
number VM.1012A. When removi ng cyl i nder number
one i njector, thread the wi ri ng harness through the
access hol e on the speci al socket (Fi g. 44).
Fig. 42 Fuel Injector SensorNumber1 Cylinder
Fig. 43 Fuel InjectorTypical
Fig. 44 Wiring Harness Through Socket
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 21
REMOVAL AND INSTALLATION (Continued)
(6) Remove and di scard the copper washer (seal ) at
bottom of i njector (Fi g. 42).
INSTALLATION
(1) Cl ean the i njector threads i n cyl i nder head.
(2) I nstal l new copper washer (seal ) to i njector.
(3) I nstal l i njector to engi ne. Ti ghten to 70 Nm
(52 ft. l bs.) torque.
(4) I nstal l hi ghpressure fuel l i nes. Refer to Hi gh-
Pressure Fuel Li nes i n thi s group for procedures.
(5) I nstal l fuel drai n hoses (tubes) to each i njector.
Do not use cl amps at fuel drai n hoses.
(6) Connect negati ve battery cabl e to battery.
(7) Bl eed the ai r from the hi ghpressure l i nes.
Refer to the Ai r Bl eed Procedure secti on of thi s
group.
FUEL TANK
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) I nsert fuel si phon hose i nto fuel fi l l er neck and
push i t i nto the tank.
(3) Drai n fuel tank dry i nto hol di ng tank or a
properl y l abel ed diesel safety contai ner.
(4) Rai se vehi cl e on hoi st.
(5) Di sconnect both the fuel fi l l and fuel vent rub-
ber hoses at the fuel tank.
(6) Di sconnect fuel suppl y and return l i nes from
the steel suppl y l i ne (Fi g. 45).
The fuel reservoir module electrical connec-
tor has a retainer that locks it in place .
(7) Sl i de el ectri cal connector l ock to unl ock.
(8) Push down on connector retai ner (Fi g. 47) and
pul l connector off modul e.
(9) Use a transmi ssi on jack to support fuel tank.
Remove bol ts from fuel tank straps.
(10) Lower tank sl i ghtl y. Careful l y remove fi l l er
hose from tank.
(11) Lower the fuel tank. Remove cl amp and
remove fuel fi l l er tube vent hose. Remove fuel tank
from vehi cl e.
INSTALLATION
(1) Posi ti on fuel tank on transmi ssi on jack. Con-
nect fuel fi l l er tube vent hose and repl ace cl amp.
(2) Rai se tank i nto posi ti on and careful l y work
fi l l er tube i nto tank. A l i ght coati ng of cl ean engi ne
oi l on the tube end may be used to ai d assembl y.
Fuel Tank
Fig. 45 Fuel Tank Connections at Front of Tank
Fig. 46 Fuel Fill/Vent Hose Index Marks
14 - 22 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
(3) Feed fi l l er vent l i ne thru frame rai l . Careful
not to cross l i nes.
(4) Ti ghten strap bol ts to 54 Nm (40 ft. l bs.)
torque. Remove transmi ssi on jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(5) Connect modul e el ectri cal connector. Pl ace
retai ner i n l ocked posi ti on.
(6) Lubri cate the fuel suppl y and return l i nes wi th
cl ean 30 wei ght engi ne oi l , i nstal l the qui ck connect
fuel fi tti ng. Refer to Tube/Fi tti ng Assembl y i n the
Fuel Del i very secti on of thi s Group.
(7) Attach fi l l er l i ne to fi l l er tube. Pul l on connec-
tor to make sure of connecti on.
(8) Fi l l fuel tank, repl ace cap, and connect battery
negati ve cabl e.
FUEL RESERVOIR MODULE
REMOVAL
WARNING: THE FUEL RESERVOIR OF THE FUEL
MODULE DOES NOT EMPTY OUT WHEN THE TANK
IS DRAINED. THE FUEL IN THE RESERVOIR WILL
SPILL OUT WHEN THE MODULE IS REMOVED.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n fuel tank dry i nto hol di ng tank or a
properl y l abel ed diesel safety contai ner.
(3) Rai se vehi cl e on hoi st.
(4) Use a transmi ssi on jack to support the fuel
tank. Remove bol ts from fuel tank straps. Lower
tank sl i ghtl y.
(5) Cl ean area around fuel reservoi r modul e and
tank to keep di rt and forei gn materi al out of tank.
(6) Di sconnect fuel l i nes from fuel modul e by
depressi ng qui ck connect retai ners wi th thumb and
fore fi nger.
(7) Sl i de modul e el ectri cal connector l ock to
unl ock.
(8) Push down on connector retai ner (Fi g. 48) and
pul l connector off modul e.
(9) Usi ng Speci al Tool 6856, remove pl asti c l ocknut
countercl ockwi se to rel ease pump modul e (Fi g. 49).
(10) Careful l y remove modul e and O-ri ng from
tank.
(11) Di scard ol d O-ri ng.
INSTALLATION
(1) Wi pe seal area of tank cl ean and pl ace a new
O-ri ng seal i n posi ti on on pump.
(2) Posi ti on fuel reservoi r modul e i n tank wi th
l ocknut.
(3) Ti ghten l ocknut to 58 Nm (43 ft. l bs.).
(4) Connect fuel l i nes.
(5) Pl ug i n el ectri cal connector. Sl i de connector
l ock i nto posi ti on.
(6) Rai se fuel tank, i nstal l bol ts i nto fuel tank
straps and ti ghten.
Fig. 47 Module Connector Retainer and Lock
Fig. 48 Module Connector Retainer and Lock
Fig. 49 Fuel Reservoir Module Lock Nut Removal
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 23
REMOVAL AND INSTALLATION (Continued)
(7) Lower vehi cl e on hoi st.
(8) Connect negati ve cabl e from battery.
(9) Fi l l fuel tank. Check for l eaks.
(10) I nstal l fuel fi l l er cap.
HIGH-PRESSURE LINES
Al l hi ghpressure fuel l i nes are of the same l ength
and i nsi de di ameter. Correct hi ghpressure fuel l i ne
usage and i nstal l ati on i s cri ti cal to smooth engi ne
operati on.
CAUTION: The highpressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
REMOVAL
(1) Di sconnect negati ve battery cabl e from battery.
(2) Remove the necessary cl amps (Fi g. 50) hol di ng
the l i nes to the engi ne.
(3) Cl ean the area around each fuel l i ne connec-
ti on. Di sconnect each l i ne at the top of each fuel
i njector (Fi g. 51).
(4) Di sconnect each hi ghpressure l i ne fi tti ng at
each fuel i njecti on pump del i very val ve.
(5) Very careful l y remove each l i ne from the
engi ne. Note the posi ti on (fi ri ng order) of each l i ne
whi l e removi ng. Do not bend the line while
removing.
CAUTION: Be sure that the highpressure fuel lines
are installed in the same order that they were
removed. Prevent the injection pump delivery valve
holders (Fig. 50) from turning when removing or
installing highpressure lines from injection pump.
INSTALLATION
(1) Careful l y posi ti on each hi ghpressure fuel l i ne
to the fuel i njector and fuel i njecti on pump del i very
val ve hol der i n the correct fi ri ng order. Al so posi ti on
each l i ne i n the correct l i ne hol der.
(2) Loosel y i nstal l the l i ne cl amp/hol der bol ts.
(3) Ti ghten each l i ne at the del i very val ve to 30
Nm (22 ft. l bs.) torque.
(4) Ti ghten each l i ne at the fuel i njector to 30 Nm
(22 ft. l bs.) torque.
Be sure the lines are not contacting each
other or any other component.
(5) Ti ghten the cl amp bracket bol ts to 24 Nm (18
ft. l bs.) torque.
(6) Bl eed ai r from the fuel system. Refer to the Ai r
Bl eed Procedure secti on of thi s group.
SPECIFICATIONS
FUEL TANK CAPACITY
75 Liters (20.0 Gals.)
Nomi nal refi l l capaci ti es are shown. A vari ati on
may be observed from vehi cl e to vehi cl e due to man-
ufacturi ng tol erances, ambi ent temperatures and
refi l l procedures.
Fig. 50 Fuel Lines and Clamps/Holders
Fig. 51 Fuel Lines at Fuel Injectors
14 - 24 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
IDLE SPEED
900 rpm 25 rpm wi th engi ne at normal operat-
i ng temperature.
FUEL INJECTOR FIRING SEQUENCE
1342
FUEL SYSTEM PRESSURE
Peak Injection Pressure/Fuel Injection Pump
Operating Pressure: 40,00045,000 kPa (5801
6526 psi ).
Opening Pressure of Fuel Injector:
15,00015,800 kPa (21752291 psi ).
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 25
SPECIFICATIONS (Continued)
FUEL INJ ECTION SYSTEM2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 26
DESCRIPTION AND OPERATION
AIR CONDITIONING (A/C) CONTROLSMSA
INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
AIR CONDITIONING RELAYMSA OUTPUT . . 31
ASD RELAYMSA INPUT . . . . . . . . . . . . . . . . 31
BATTERY VOLTAGEPCM INPUT . . . . . . . . . . 28
BRAKE SWITCHMSA INPUT . . . . . . . . . . . . . 30
DATA LINK CONNECTORPCM AND MSA
INPUT AND OUTPUT . . . . . . . . . . . . . . . . . . 30
ELECTRIC VACUUM MODULATOR (EVM)MSA
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE COOLANT GAUGEPCM OUTPUT . . 31
ENGINE COOLANT TEMPERATURE SENSOR
MSA/PCM INPUT . . . . . . . . . . . . . . . . . . . . . 29
ENGINE OIL PRESSURE GAUGEPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ENGINE SPEED/CRANK POSITION SENSOR
MSA INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FIVE VOLT POWERMSA/PCM OUTPUT . . . . 31
FUEL INJECTOR SENSORGROUND . . . . . . 29
FUEL TIMING SOLENOIDMSA OUTPUT . . . . 31
GLOW PLUG LAMPPCM OUTPUT . . . . . . . . 31
GLOW PLUG RELAYMSA OUTPUT . . . . . . . . 32
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 32
IGNITION CIRCUIT SENSE
MSA/PCM INPUT . . . . . . . . . . . . . . . . . . . . 28
IGNITION CIRCUIT SENSEPCM INPUT . . . . 28
MASS AIR FLOW SENSOR . . . . . . . . . . . . . . . 28
NEEDLE MOVEMENT OR INTRUMENTED
FIRST INJECTORMSA INPUT . . . . . . . . . . 28
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . 28
POWERTRAIN CONTROL MODULE (PCM) . . . 27
SENSOR RETURNMSA/PCM INPUT
(ANALOG GROUND) . . . . . . . . . . . . . . . . . . . 28
SPEED CONTROLMSA INPUT . . . . . . . . . . . 30
SPEED CONTROLPCM OUTPUTS . . . . . . . . 31
TACHOMETERPCM OUTPUT . . . . . . . . . . . . 32
VEHICLE SPEED SENSORMSA INPUT . . . . . 30
VEHICLE THEFT ALARM . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING
ASD RELAY TEST . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . 36
DIESEL DIAGONSTICS . . . . . . . . . . . . . . . . . . 33
ENGINE COOLANT TEMPERATURE SENSOR
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE SPEED SENSOR TEST . . . . . . . . . . . 33
GLOW PLUG RELAY TEST . . . . . . . . . . . . . . . 34
GLOW PLUG TEST . . . . . . . . . . . . . . . . . . . . . 34
MASS AIR FLOW SENSOR . . . . . . . . . . . . . . . 36
RELAYSOPERATION/TESTING . . . . . . . . . . . 35
VEHICLE SPEED SENSOR TEST . . . . . . . . . . . 36
REMOVAL AND INSTALLATION
A/C CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . 36
ASD RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE COOLANT TEMPERATURE SENSOR . 37
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . 37
GLOW PLUG RELAY . . . . . . . . . . . . . . . . . . . . 38
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 38
POWERTRAIN CONTROL MODULE (PCM) . . . 38
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . 39
SPECIFICATIONS
GLOW PLUG CURRENT DRAW . . . . . . . . . . . . 40
TORQUE CHART2.5L DIESEL . . . . . . . . . . . . 40
GENERAL INFORMATION
INTRODUCTION
Thi s secti on wi l l cover components ei ther regul ated
or control l ed by the MSA control l er and the Power-
trai n Control Modul e (PCM). The fuel heater rel ay
and fuel heater are not operated by the MSA control -
l er or the PCM. These components are control l ed by
the i gni ti on (key) swi tch. Al l other fuel system el ec-
tri cal components necessary to operate the engi ne
are control l ed or regul ated by the MSA control l er,
whi ch i nterfaces wi th the PCM. Refer to the fol l ow-
i ng descri pti on for more i nformati on.
Certai n fuel system component fai l ures may cause
a no start, or prevent the engi ne from runni ng. I t i s
i mportant to know that the MSA has a feature
where, i f possi bl e, i t wi l l i gnore the fai l ed sensor, set
a code rel ated to the sensor, and operate the engi ne
i n a Li mp Home mode. When the MSA i s operati ng
i n a Li mp Home mode, the Check Engi ne Lamp on
the i nstrument panel may be constantl y i l l umi nated,
and the engi ne wi l l most l i kel y have a noti ceabl e l oss
of performance. An exampl e of thi s woul d be an
Accel erator Pedal Posi ti on Sensor fai l ure, and i n that
si tuati on, the engi ne woul d run at a constant 1100
RPM, regardl ess of the actual posi ti on of the pedal .
Thi s i s the most extreme of the three Li mp Home
modes.
When the Check Engi ne Lamp i s i l l umi nated con-
stantl y wi th the key on and the engi ne runni ng, i t
14 - 26 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
usual l y i ndi cates a probl em has been detected some-
where wi thi n the fuel system. The DRBI I I scan tool
i s the best method for communi cati ng wi th the MSA
and PCM to di agnose faul ts wi thi n the system.
DESCRIPTION AND OPERATION
POWERTRAIN CONTROL MODULE (PCM)
The MSA control l er i s mounted under the l eft si de
rear seat (Fi g. 1). The Powertrai n Control Modul e
(PCM) i s mounted i n the engi ne compartment. (Fi g.
2).
The MSA Control l er i s a preprogrammed, di gi tal
computer. I t wi l l ei ther di rectl y operate or parti al l y
regul ate the:
Speed Control
Speed Control l amp
Fuel Ti mi ng Sol enoi d
Check Engi ne Li ght
Gl ow Pl ug Rel ay
Gl ow Pl ugs
Gl ow Pl ug Lamp
ASD Rel ay
Ai r Condi ti oni ng
Tachometer
El ectri c Vacuum Modul ator (EVM)
The MSA can adapt i ts programmi ng to meet
changi ng operati ng condi ti ons.
The MSA recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
MSA regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as MSA Outputs. The sensors
and swi tches that provi de i nputs to the MSA are con-
si dered MSA Inputs.
MSA Inputs are:
Ai r Condi ti oni ng Sel ecti on
Theft Al arm
ASD Rel ay
Control Sl eeve Posi ti on Sensor
Fuel Temperature Sensor
Mass Ai r Fl ow Sensor
Accel erator Pedal Posi ti on Sensor
Engi ne Cool ant Temperature Sensor
Low I dl e Posi ti on Swi tch
5 Vol t Suppl y
Vehi cl e Speed Sensor
Engi ne Speed/Crank Posi ti on Sensor (rpm)
Needl e Movement Sensor
Starter Si gnal
Brake Swi tch
Speed Control Swi tch
Power Ground
I gni ti on (key) Swi tch Sense
MSA Outputs:
After i nputs are recei ved by the MSA and PCM,
certai n sensors, swi tches and components are con-
trol l ed or regul ated by the MSA and PCM. These are
consi dered MSA Outputs. These outputs are for:
A/C Cl utch Rel ay (for A/C cl utch operati on)
Speed Control Lamp
ASD Rel ay
5 Vol ts Suppl y
Fuel Quanti ty Actuator
Fuel Ti mi ng Sol enoi d
Fuel Shutdown Sol enoi d
Gl ow Pl ug Lamp
Check Engi ne Lamp (On/Off si gnal )
Fig. 1 MSA Controller Location
Fig. 2 PCM Location
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 27
GENERAL INFORMATION (Continued)
El ectri c Vacuum Modul ator (EVM)
Gl ow Pl ug Rel ay
Tachometer
The PCM sends and reci eves si gnal s to and from
the MSA control l er. PCM inputs are:
Power Gound
5 Vol ts Suppl y
Vehi cl e Speed Sensor
Water-I n-Fuel Sensor
Cool ant Temperature Sensor
Low Cool ant Sensor
Sensor Return
Fuel Level Sensor
Oi l Pressure Sensor
Tachometer Si gnal
Gl ow Pl ug Lamp
Check Engi ne Lamp (On/Off si gnal )
Brake On/Off Swi tch
Battery Vol tage
ASD Rel ay
PCM Outputs:
A/C On Si gnal
Vehi cl e Theft Al arm Ok to Run si gnal
Body Control Modul e CCD Bus (+)
Body Control Modul e CCD Bus ()
Scan Tool Data Li nk Reci eve
Scan Tool Data Li nk Transmi t
Low Cool ant Lamp
Generator Control
MASS AIR FLOW SENSOR
The Mass Ai r Fl ow Sensor i s a gauge that mea-
sures ai r densi ty. I n the Mass Ai r Fl ow Sensor (MAF)
there i s a cerami c el ement that changes i ts resi s-
tance based on temperature. The cerami c el ement i s
part of an el ectroni c ci rcui t connected to the MSA,
and has a vol tage appl i ed to i t. The MAF sensor i s
connected i n l i ne wi th the engi nes ai r i ntake tube,
and when the engi ne i s at i dl e, there i s a rel ati vel y
l ow amount of ai r fl owi ng across the cerami c el e-
ment. Thi s ai r has a cool i ng effect on the cerami c el e-
ment, and i ts resi stance changes, and a vol tage
si gnal i s sent to the MSA. As a general rul e, when
the engi ne i s runni ng at a hi gh RPM, the vol tage si g-
nal sent by the MAF sensor i s hi gh. When the engi ne
i s runni ng at a l ow RPM, the vol tage si gnal sent by
the MAF i s l ow. The MSA can cal cul ate the mass
(actual wei ght) of the ai r fl owi ng through the MAF
sensor based on the val ue of the vol tage si gnal .
VEHICLE THEFT ALARM
The PCM can l earn i f the vehi cl e has a Vehi cl e
Theft Al arm (VTA) system. Once i t detects the vehi -
cl e havi ng VTA, the controller can ONLY BE
USED ON VEHICLES WITH VTA.
I f the PCM i s put i t on a vehi cl e wi thout VTA the
Gl ow Pl ug Lamp wi l l start to bl i nk and the vehi cl e
wi l l not start.
The PCM cannot be fl ashed to remove the VTA.
BATTERY VOLTAGE PCM INPUT
The battery vol tage i nput provi des power to the
PCM. I t al so i nforms the PCM what vol tage l evel i s
bei ng suppl i ed by the generator once the vehi cl e i s
runni ng.
The battery i nput al so provi des the vol tage that i s
needed to keep the PCM memory al i ve. The memory
stores Di agnosti c Troubl e Code (DTC) messages.
Troubl e codes wi l l sti l l be stored even i f the battary
vol tage i s l ost.
SENSOR RETURN MSA/PCM INPUT (ANALOG
GROUND)
Sensor Return provi des a l ow noi se Anal og ground
reference for al l system sensors.
IGNITION CIRCUIT SENSE MSA/PCM INPUT
The i gni ti on ci rcui t sense i nput si gnal s the MSA
and PCM that the i gni ti on (key) swi tch has been
turned to the ON posi ti on. Thi s si gnal i ni ti ates the
gl ow pl ug control routi ne to begi n the preheat
cycl e.
IGNITION CIRCUIT SENSE PCM INPUT
The i gni ti on ci rcui t sense i nput si gnal s the PCM
that the i gni ti on (key) swi tch has been turned to the
ON posi ti on. Thi s si gnal i ni ti ates the gl ow pl ug con-
trol routi ne to begi n the preheat cycl e.
POWER GROUND
Provi des a common ground for power devi ces (sol e-
noi d and rel ay devi ces).
NEEDLE MOVEMENT OR INTRUMENTED FIRST
INJECTOR MSA INPUT
Thi s i nput from the MSA suppl i es a constant 30
mA el ectri cal current source for the fi rst i njector sen-
sor. I t wi l l vary the vol tage to thi s sensor when i t
senses a mechani cal movement wi thi n the i njector
needl e (pi ntl e) of the number1 cyl i nder fuel i njector.
When thi s vol tage has been determi ned by the MSA,
i t wi l l then control an output to the fuel ti mi ng sol e-
noi d (the fuel ti mi ng sol enoi d i s l ocated on the fuel
i njecti on pump). Al so refer to Fuel I njecti on Pump for
addi ti onal i nformati on.
The fi rst i njector sensor i s a magneti c (i nducti ve)
type.
The fi rst i njector sensor i s used onl y on the fuel
i njector for the number1 cyl i nder (Fi g. 3). I t i s not
used on the i njectors for cyl i nders number 2, 3, or 4.
14 - 28 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
FUEL INJECTOR SENSOR GROUND
Provi des a l ow noi se ground for the fuel i njector
sensor onl y.
ENGINE COOLANT TEMPERATURE SENSOR MSA/
PCM INPUT
The 05 vol t i nput from thi s sensor tel l s the MSA
and PCM the temperature of the engi ne cool ant.
Based on the vol tage recei ved at the MSA, i t wi l l
then determi ne operati on of the fuel ti mi ng sol enoi d,
gl ow pl ug rel ay, el ectri cal vacuum modul ator (emi s-
si on component) and generator (chargi ng system).
The sensor i s l ocated on the si de of the #3 cyl i nder
head near the rear of fuel i njecti on pump (Fi g. 4).
ENGINE SPEED/CRANK POSITION SENSOR MSA
INPUT
The engi ne speed sensor i s mounted to the trans-
mi ssi on bel l housi ng at the l eft/rear si de of the engi ne
bl ock (Fi g. 5).
The engi ne speed sensor produces i ts own output
si gnal . I f thi s si gnal i s not recei ved, the MSA wi l l not
al l ow the engi ne to start.
The engi ne speed sensor i nput i s used i n conjunc-
ti on wi th the fi rst i njector sensor to establ i sh fuel
i njecti on pump ti mi ng.
The fl ywheel has four notches at i ts outer edge (Fi g.
6). Each notch i s spaced equal l y every 90. The notches
cause a pul se to be generated when they pass under the
speed sensor (Fi g. 6). These pul ses are the i nput to the
MSA. The i nput from thi s sensor determi nes crankshaft
posi ti on (i n degrees) by moni tori ng the notches.
Fig. 3 Fuel Injector Sensor
Fig. 4 Engine Coolant Temperature Sensor Location
Fig. 5 Engine Speed Sensor Location
Fig. 6 Speed Sensor Operation
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 29
DESCRIPTION AND OPERATION (Continued)
The sensor al so generates an rpm si gnal to the
MSA. Thi s si gnal i s used as an i nput for the control
of the generator fi el d, vehi cl e speed control , and
i nstrument panel mounted tachometer.
I f the engi ne speed sensor shoul d fai l , the system
i s unabl e to compensate for the probl em and the car
wi l l stop.
AIR CONDITIONING (A/C) CONTROLS MSA
INPUTS
The A/C control system i nformati on appl i es to fac-
tory i nstal l ed ai r condi ti oni ng uni ts.
A/C REQUEST SIGNAL: When ei ther the A/C or
Defrost mode has been sel ected and the A/C l ow and
hi ghpressure swi tches are cl osed, an i nput si gnal i s
sent to the MSA. The MSA uses thi s i nput to cycl e
the A/C compressor through the A/C rel ay.
I f the A/C l ow or hi ghpressure swi tch opens, the
MSA wi l l not recei ve an A/C request si gnal . The PCM
wi l l then remove the ground from the A/C rel ay. Thi s
wi l l deacti vate the A/C compressor cl utch. Al so, i f the
engi ne cool ant reaches a temperature outsi de normal
of i ts normal range, or i t overheats, the MSA wi l l
deacti vate the A/C cl utch.
BRAKE SWITCH MSA INPUT
When the brake l i ght swi tch i s acti vated, the MSA
recei ves an i nput i ndi cati ng that the brakes are
bei ng appl i ed. After recei vi ng thi s i nput, the MSA i s
used to control the speed control system. There i s a
Pri mary and a Secondary brake swi tch. The Second-
ary brake swi tch i s cl osed unti l the brake pedal i s
pressed.
DATA LINK CONNECTOR PCM AND MSA INPUT
AND OUTPUT
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool wi th the PCM and MSA. The data
l i nk connector i s l ocated under the i nstrument panel
near the bottom of steeri ng col umn. (Fi g. 7).
VEHICLE SPEED SENSOR MSA INPUT
The vehi cl e speed sensor i s l ocated i n the extensi on
housi ng of the transmi ssi on (2WD) (Fi g. 8) or on the
transfer case extensi on housi ng. The sensor i nput i s
used by the MSA to determi ne vehi cl e speed and di s-
tance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the accel erator pedal posi -
ti on sensor, i ndi cate an i dl e decel erati on to the MSA.
When the vehi cl e i s stopped at i dl e, a rel eased pedal
si gnal i s recei ved by the MSA (but a speed sensor
si gnal i s not recei ved).
I n addi ti on to determi ni ng di stance and vehi cl e
speed, the output from the sensor i s used to control
speed control operati on.
SPEED CONTROL MSA INPUT
The speed control system provi des fi ve separate
i nputs to the MSA: On/Off, Set, Resume/Accel , Can-
cel , and Decel .. The On/Off i nput i nforms the MSA
that the speed control system has been acti vated.
The Set i nput i nforms the MSA that a fi xed vehi cl e
speed has been sel ected. The Resume i nput i ndi cates
Fig. 7 Data Link Connector Location
Fig. 8 Vehicle Speed SensorTypical
14 - 30 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
to the MSA that the previ ous fi xed speed i s
requested.
Speed control operati on wi l l start at 50 km/h142
km/h (3585 mph). The upper range of operati on i s
not restri cted by vehi cl e speed. I nputs that effect
speed control operati on are vehi cl e speed sensor and
accel erator pedal posi ti on sensor.
Refer to Group 8H for further speed control i nfor-
mati on.
ASD RELAY MSA INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the MSA
that the ASD rel ay has been acti vated. The ASD
rel ay i s l ocated i n the PDC. The PDC i s l ocated next
to the battery i n the engi ne compartment. For the
l ocati on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the MSA does not see 12 vol ts (+) at
thi s i nput when the ASD rel ay shoul d be acti vated, i t
wi l l set a Di agnosti c Troubl e Code (DTC).
FIVE VOLT POWER MSA/PCM OUTPUT
Thi s ci rcui t suppl i es approxi matel y 5 vol ts to
power the Accel erator Pedal Posti on Sensor, and
Mass Ai r Fl ow Sensor.
ENGINE COOLANT GAUGE PCM OUTPUT
Refer to the I nstrument Panel and Gauges group
for addi ti onal i nformati on.
ENGINE OIL PRESSURE GAUGE PCM OUTPUT
Refer to the I nstrument Panel and Gauges group
for addi ti onal i nformati on.
GLOW PLUG LAMP PCM OUTPUT
The Gl ow Pl ug l amp (mal functi on i ndi cator l amp)
i l l umi nates on the message center each ti me the i gni -
ti on (key) swi tch i s turned on. I t wi l l stay on for
about two seconds as a bul b test.
I f the PCM recei ves an i ncorrect si gnal , or no si gnal
from certai n sensors or components, the l amp BLI NKS.
Thi s i s a warni ng that the PCM has recorded a system
or sensor mal functi on. I t si gnal s an i mmedi ate need for
servi ce. There are onl y 5 HARD faul ts that can turn on
thi s l amp to make i t bl i nk.
SPEED CONTROL PCM OUTPUTS
These two ci rcui ts control the fuel quanti ty actua-
tor to regul ate vehi cl e speed. Refer to Group 8H for
Speed Control i nformati on.
AIR CONDITIONING RELAY MSA OUTPUT
Thi s ci rcui t control s a ground si gnal for operati on of
the A/C cl utch rel ay. Al so refer to Ai r Condi ti oni ng
(A/C) Control sMSA I nput for addi ti onal i nformati on.
The A/C rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated next to the battery
i n the engi ne compartment. For the l ocati on of the
rel ay wi thi n the PDC, refer to l abel on PDC cover.
FUEL TIMING SOLENOID MSA OUTPUT
The fuel ti mi ng sol enoi d i s l ocated on the bottom of
the fuel i njecti on pump (Fi g. 11).
Fig. 9 Vehicle Speed Sensor4 Wheel Drive
Fig. 10 Glow Plug Lamp Symbol
Fig. 11 Fuel Timing Solenoid
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 31
DESCRIPTION AND OPERATION (Continued)
Thi s 12(+) vol t, pul se wi dth modul ated (dutycycl e)
output control s the amount of fuel ti mi ng (advance)
i n the fuel i njecti on pump. The hi gher the duty-
cycl e, the l ower the advance. The l ower the duty-
cycl e, the more advanced the fuel ti mi ng.
The dutycycl e i s determi ned by the MSA from
i nputs i t recei ves from the fuel i njector sensor and
engi ne speed sensor.
TACHOMETER PCM OUTPUT
The PCM reci eves engi ne rpm val ues from the
MSA control l er, and then suppl i es engi ne rpm val ues
to the Body Control l er that then suppl i es the i nstru-
ment cl uster mounted tachometer (i f equi pped). Refer
to Group 8E for tachometer i nformati on.
GLOW PLUG RELAY MSA OUTPUT
When the i gni ti on (key) swi tch i s pl aced i n the ON
posi ti on, a si gnal i s sent to the MSA rel ati ng current
engi ne cool ant temperature. Thi s si gnal i s sent from
the engi ne cool ant temperature sensor.
After recei vi ng thi s si gnal , the MSA wi l l determi ne
i f, when and for how l ong a peri od the gl ow pl ug
rel ay shoul d be acti vated. Thi s i s done before, duri ng
and after the engi ne i s started. Whenever the gl ow
pl ug rel ay i s acti vated, i t wi l l control the 12V+ 100
amp ci rcui t for the operati on of the four gl ow pl ugs.
Wi th a col d engi ne, the gl ow pl ug rel ay and gl ow
pl ugs may be acti vated for a maxi mum ti me of 200
seconds. Refer to the fol l owi ng Gl ow Pl ug Control
chart for a temperature/ti me compari son of gl ow pl ug
rel ay operati on.
I n thi s chart, PreHeat and PostHeat ti mes are
menti oned. Preheat i s the amount of ti me the gl ow
pl ug rel ay ci rcui t i s acti vated when the i gni ti on (key)
swi tch i s ON, but the engi ne has yet to be started.
Postheat i s the amount of ti me the gl ow pl ug rel ay
ci rcui t i s acti vated after the engi ne i s operati ng. The
Gl ow Pl ug l amp wi l l not be i l l umi nated duri ng the
postheat cycl e.
GLOW PLUGS
Gl ow pl ugs are used to hel p start a col d or cool
engi ne. The pl ug wi l l heat up and gl ow to heat the
combusti on chamber of each cyl i nder. An i ndi vi dual
pl ug i s used for each cyl i nder. Each pl ug i s threaded
i nto the cyl i nder head above the fuel i njector (Fi g.
13).
Each pl ug wi l l momentari l y draw approxi matel y 25
amps of el ectri cal current duri ng the i ni ti al keyon
cycl e. Thi s i s on a col d or cool engi ne. After heati ng,
Fig. 12 Glow Plug Relay Location
GLOW PLUG CONTROL
Fig. 13 Glow Plug
14 - 32 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DESCRIPTION AND OPERATION (Continued)
the current draw wi l l drop to approxi matel y 912
amps per pl ug.
Total momentary current draw for al l four pl ugs i s
approxi matel y 100 amps on a col d engi ne droppi ng to
a total of approxi matel y 40 amps after the pl ugs are
heated.
El ectri cal operati on of the gl ow pl ugs are con-
trol l ed by the gl ow pl ug rel ay. Refer to the previ ous
Gl ow Pl ug Rel ayMSA Output for addi ti onal i nfor-
mati on.
ELECTRIC VACUUM MODULATOR (EVM) MSA
OUTPUT
Thi s ci rcui t control s operati on of the El ectri c Vac-
uum Modul ator (EVM). The EVM (Fi g. 12) control s
operati on of the EGR val ve.
Refer to Group 25, Emi ssi on Control System for
i nformati on. See El ectri c Vacuum Modul ator.
DIAGNOSIS AND TESTING
DIESEL DIAGONSTICS
The MSA control l ers perform engi ne off di agonsti c
tests, whi ch may be heard for about 60 seconds after
turni ng the key off.
ASD RELAY TEST
To perform a test of the rel ay and i ts rel ated ci r-
cui try, refer to the DRB scan tool . To test the rel ay
onl y, refer to Rel aysOperati on/Testi ng i n thi s sec-
ti on of the group.
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
ENGINE SPEED SENSOR TEST
To perform a test of the engi ne speed sensor and
i ts rel ated ci rcui try, refer to the DRB scan tool .
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
ENGINE COOLANT TEMPERATURE SENSOR TEST
The sensor i s l ocated on the si de of cyl i nder head
near the rear of fuel i njecti on pump (Fi g. 14).
For a l i st of Di agnosti c Troubl e Codes (DTCs) for
certai n fuel system components, refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System.
To test the sensor onl y, refer to the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor.
(2) Test the resi stance of the sensor wi th a hi gh
i nput i mpedance (di gi tal ) vol tohmmeter. The resi s-
tance (as measured across the sensor termi nal s)
shoul d be l ess than 1340 ohms wi th the engi ne
warm. Refer to the fol l owi ng Sensor Resi stance
(OHMS) chart. Repl ace the sensor i f i t i s not wi thi n
the range of resi stance speci fi ed i n the chart.
(3) Test conti nui ty of the wi re harness. Do thi s
between the MSA wi re harness connector and the
sensor connector termi nal . Al so test conti nui ty of
wi re harness to the sensor connector termi nal . Refer
Fig. 14 Engine Coolant Temperature Sensor
Location
SENSOR RESISTANCE (OHMS)
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 33
DESCRIPTION AND OPERATION (Continued)
to Group 8W for wi ri ng connector and ci rcui try i nfor-
mati on. Repai r the wi re harness i f an open ci rcui t i s
i ndi cated.
(4) After tests are compl eted, connect el ectri cal
connector to sensor.
GLOW PLUG TEST
Hard starti ng or a rough i dl e after starti ng may be
caused by one or more defecti ve gl ow pl ugs. Before
testi ng the gl ow pl ugs, a test of the gl ow pl ug rel ay
shoul d be performed. Thi s wi l l ensure that 12V+ i s
avai l abl e at the pl ugs when starti ng the engi ne.
Refer to the Gl ow Pl ug Rel ay Test for i nformati on.
For accurate test resul ts, the gl ow pl ugs shoul d be
removed from the engi ne. The pl ugs must be checked
when col d. Do not check the plugs if the engine
has recently been operated. If plugs are
checked when warm, incorrect amp gauge
readings will result.
Use Churchi l l Gl ow Pl ug Tester DX.900 or an
equi val ent (Fi g. 15) for the fol l owi ng tests. Thi s
tester i s equi pped wi th 4 ti mer l amps.
(1) Remove the gl ow pl ugs from the engi ne. Refer
to Gl ow Pl ug Removal /I nstal l ati on.
(2) Attach the red l ead of the tester to the 12V+
(posi ti ve) si de of the battery.
(3) Attach the bl ack l ead of the tester to the 12V
(negati ve) si de of the battery.
(4) Fi t the gl ow pl ug i nto the top of the tester and
secure i t wi th the spri ng l oaded bar (Fi g. 15).
(5) Attach the thi rd l ead wi re of the tester to the
el ectri cal termi nal at the end of the gl ow pl ug.
(6) When performi ng the test, the tester button
(Fi g. 15) shoul d be hel d conti nuousl y wi thout rel ease
for 20 seconds as i ndi cated by the 4 ti mer l amps.
Each i l l umi nated l amp represents a 5 second ti me
l apse.
(a) Press and hol d the tester button (Fi g. 15)
and note the amp gauge readi ng. The gauge read-
i ng shoul d i ndi cate a momentary, i ni ti al current
draw (surge) of approxi matel y 25 amps. After the
i ni ti al surge, the amp gauge readi ng shoul d begi n
to fal l off. The gl ow pl ug ti p shoul d start to gl ow
an orange col or after 5 seconds. I f the ti p di d not
gl ow after 5 seconds, repl ace the gl ow pl ug. Before
di scardi ng the gl ow pl ug, check the posi ti on of the
ci rcui t breaker on the bottom of the pl ug tester. I t
may have to be reset. Reset i f necessary.
(b) Conti nue to hol d the tester button whi l e
observi ng the amp gauge and the 4 ti mer l amps.
When al l 4 l amps are i l l umi nated, i ndi cati ng a 20
second ti me l apse, the amp gauge readi ng shoul d
i ndi cate a 912 amp current draw. I f not, repl ace
the gl ow pl ug. Refer to Gl ow Pl ug Removal /I nstal -
l ati on.
(7) Check each gl ow pl ug i n thi s manner usi ng one
20 second cycl e. I f the gl ow pl ug i s to be retested, i t
must fi rst be al l owed to cool to room temperature.
WARNING: THE GLOW PLUG WILL BECOME
EXTREMELY HOT (GLOWING) DURING THESE
TESTS. BURNS COULD RESULT IF IMPROPERLY
HANDLED. ALLOW THE GLOW PLUG TO COOL
BEFORE REMOVING FROM TESTER.
(8) Remove the gl ow pl ug from the tester.
GLOW PLUG RELAY TEST
The gl ow pl ug rel ay i s l ocated i n the engi ne com-
partment on the l efti nner fender (Fi g. 16).
When the i gni ti on (key) swi tch i s pl aced i n the ON
posi ti on, a si gnal i s sent to the MSA rel ati ng current
engi ne cool ant temperature. Thi s si gnal i s sent from
the engi ne cool ant temperature sensor.
After recei vi ng thi s si gnal , the MSA wi l l determi ne
i f, when and for how l ong a peri od the gl ow pl ug
rel ay shoul d be acti vated. Thi s i s done before, duri ng
and after the engi ne i s started. Whenever the gl ow
pl ug rel ay i s acti vated, i t wi l l control the 12V+ 100
amp ci rcui t for the operati on of the four gl ow pl ugs.
The Gl ow Pl ug l amp i s ti ed to thi s ci rcui t. Lamp
operati on i s al so control l ed by the MSA.
Wi th a col d engi ne, the gl ow pl ug rel ay and gl ow
pl ugs may be acti vated for a maxi mum ti me of 200
seconds. Refer to the Gl ow Pl ug Control chart for a
temperature/ti me compari son of gl ow pl ug rel ay oper-
ati on.
I n thi s chart, PreHeat and PostHeat ti mes are
menti oned. Preheat i s the amount of ti me the gl ow
Fig. 15 Typical Glow Plug Tester
14 - 34 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
pl ug rel ay ci rcui t i s acti vated when the i gni ti on (key)
swi tch i s ON, but the engi ne has yet to be started.
Postheat i s the amount of ti me the gl ow pl ug rel ay
ci rcui t i s acti vated after the engi ne i s operati ng. The
Gl ow Pl ug l amp wi l l not be i l l umi nated duri ng the
postheat cycl e.
TESTING:
Di sconnect and i sol ate the el ectri cal connectors
(Fi g. 17) at al l four gl ow pl ugs. Wi th the engi ne cool
or col d, and the key i n the ON posi ti on, check for
1012 vol ts + at each el ectri cal connector. 1012 vol ts
+ shoul d be at each connector whenever the MSA i s
operati ng i n the preheat or postheat cycl es (refer
to the fol l owi ng Gl ow Pl ug Control chart). Be very
careful not to allow any of the four discon-
nected glow plug electrical connectors to con-
tact a metal surface. When the key is turned to
the ON position, approximately 100 amps at 12
volts is supplied to these connectors. I f 1012
vol ts + i s not avai l abl e at each connector, check con-
ti nui ty of wi ri ng harness di rectl y to the rel ay. I f con-
ti nui ty i s good di rectl y to the rel ay, the faul t i s ei ther
wi th the rel ay or the rel ay i nput from the MSA. To
test the rel ay onl y, refer to Rel aysOperati on/Test-
i ng i n thi s secti on of the group. I f the rel ay test i s
good, refer to the DRB scan tool .
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
RELAYS OPERATION/TESTING
The following description of operation and
tests apply only to the ASD and other relays .
The termi nal s on the bottom of each rel ay are num-
bered (Fi g. 18).
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and other rel ays, termi nal 30
i s connected to battery vol tage at al l ti mes.
The MSA grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and other
rel ays, termi nal number 87A connects to termi nal 30.
Thi s i s the Off posi ti on. I n the off posi ti on, vol tage i s
not suppl i ed to the rest of the ci rcui t. Termi nal 87A
i s the center termi nal on the rel ay.
Fig. 16 Glow Plug Relay Location
Fig. 17 Wiring Connection at Glow Plug
GLOW PLUG CONTROL
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 35
DIAGNOSIS AND TESTING (Continued)
When the MSA energi zes the ASD and other
rel ays, termi nal 87 connects to termi nal 30. Thi s i s
the On posi ti on. Termi nal 87 suppl i es vol tage to the
rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
other rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and other rel ay ci rcui ts. Refer to group 8W, Wi ri ng
Di agrams.
MASS AIR FLOW SENSOR
The Mass Ai r Fl ow (MAF) sensor can onl y be
tested by checki ng for a faul t code stored i n the
MSA. I f the mass ai r fl ow sensor stops functi oni ng,
you wi l l experi ence a l oss of power, as i f you had no
turbocharger operati on. The MSA may i ndi cate no
turbo operati on i f there i s no si gnal from the MAF
sensor. I f the sensor sets a faul t and no l oss of power
then check to see i f there i s a cl ogged ai r fi l ter.
VEHICLE SPEED SENSOR TEST
To perform a test of the sensor and i ts rel ated ci r-
cui try, refer to DRB scan tool .
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
DIAGNOSTIC TROUBLE CODES
For a l i st of Di agnosti c Troubl e Codes (DTCs),
refer to Group 25, Emi ssi on Control System for i nfor-
mati on. See On-Board Di agnosti cs.
REMOVAL AND INSTALLATION
ASD RELAY
The ASD rel ay i s l ocated i n the PDC. For the l oca-
ti on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
A/C CLUTCH RELAY
The A/C cl utch rel ay i s l ocated i n the PDC. For the
l ocati on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
Fig. 18 ASD and Other Relay Terminals
14 - 36 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
DIAGNOSIS AND TESTING (Continued)
ENGINE SPEED SENSOR
The engi ne speed sensor i s mounted to the trans-
mi ssi on bel l housi ng at the rear of the engi ne bl ock
(Fi g. 19).
REMOVAL
(1) Di sconnect the harness (on the sensor) from
the mai n el ectri cal harness.
(2) Remove the sensor mounti ng bol ts.
(3) Remove the sensor.
INSTALLATION
(1) I nstal l the sensor fl ush agai nst the openi ng i n
the transmi ssi on housi ng.
(2) I nstal l and ti ghten the sensor mounti ng bol t to
19 Nm (14 ft. l bs.) torque.
(3) Connect the el ectri cal connector to the sensor.
ENGINE COOLANT TEMPERATURE SENSOR
The sensor i s l ocated on the si de of cyl i nder head
near the rear of fuel i njecti on pump (Fi g. 20).
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
(1) Parti al l y drai n cool i ng system. Refer to Group
7, Cool i ng.
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor from cyl i nder head.
INSTALLATION
(1) I nstal l a new copper gasket to sensor.
(2) I nstal l sensor to cyl i nder head.
(3) Ti ghten sensor to 18 Nm (13 ft. l bs.) torque.
(4) Connect el ectri cal connector to sensor.
(5) Repl ace any l ost engi ne cool ant. Refer to Group
7, Cool i ng System.
Fig. 19 Engine Speed Sensor
Fig. 20 Engine Coolant Temperature Sensor
Location
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 37
REMOVAL AND INSTALLATION (Continued)
GLOW PLUGS
The gl ow pl ugs are l ocated above each fuel i njector
(Fi g. 21). Four i ndi vi dual pl ugs are used.
REMOVAL
(1) Di sconnect the negati ve battery cabl e at the
battery.
(2) Cl ean the area around the gl ow pl ug wi th com-
pressed ai r before removal .
(3) Di sconnect el ectri cal connector (Fi g. 22) at gl ow
pl ug.
(4) Remove the gl ow pl ug (Fi g. 21) from cyl i nder
head.
INSTALLATION
(1) Appl y hi ghtemperature anti sei ze compound
to gl ow pl ug threads before i nstal l ati on
(2) I nstal l the gl ow pl ug i nto the cyl i nder head.
Ti ghten to 23 Nm (203 i n. l bs.) torque.
(3) Connect battery cabl e to battery.
GLOW PLUG RELAY
The gl ow pl ug rel ay i s l ocated i n the engi ne com-
partment on the l efti nner fender (Fi g. 23).
REMOVAL
(1) Di sconnect the negati ve battery cabl e at the
battery.
(2) Remove rel ay mounti ng bol t.
(3) Di sconnect el ectri cal connector at rel ay and
remove rel ay.
INSTALLATION
(1) Check condi ti on of el ectri cal connector for dam-
age or corrosi on. Repai r as necessary.
(2) I nstal l el ectri cal connector to rel ay.
(3) I nstal l rel ay to i nner fender.
(4) Connect battery cabl e to battery.
POWERTRAIN CONTROL MODULE (PCM)
The PCM i s mounted to a bracket l ocated i n the
center consol e i n front of the ai r bag modul e (Fi g.
24).
REMOVAL
(1) Di sconnect the negati ve battery cabl e at the
battery.
(2) Loosen the 60Way connector (Fi g. 24). The
el ectri cal connector has a sl i di ng bar whi ch moves
i nward to l ock or outward to unl ock.
(3) Remove the el ectri cal connector by pul l i ng
strai ght out.
(4) Remove PCM.
Fig. 21 Glow Plug
Fig. 22 Glow Plug Electrical Connector
Fig. 23 Glow Plug Relay Location
14 - 38 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) After the PCM el ectri cal connector has been
separated from the PCM, i nspect the pi ns for corro-
si on, bei ng spread apart, bent or mi sal i gned. Al so
i nspect the pi n hei ghts i n the connector. I f the pi n
hei ghts are di fferent, thi s woul d i ndi cate a pi n has
separated from the connector. Repai r as necessary.
(2) Engage 60way connector i nto PCM. Move
sl i de bar to l ock connector.
(3) Connect negati ve cabl e to battery.
VEHICLE SPEED SENSOR
The vehi cl e speed sensor (Fi g. 25) i s l ocated on the
extensi on housi ng of the transmi ssi on for 2 wheel
dri ve vehi cl e, or on the transfer case housi ng for 4
wheel dri ve vehi cl es (Fi g. 26).
Fig. 24 PCM Location Fig. 25 Vehicle Speed Sensor Location2 Wheel
Drive
Fig. 26 Vehicle Speed Sensor Location4WD
ZG FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 39
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Rai se and support vehi cl e.
(2) Cl ean the area around the sensor before
removal .
(3) Di sconnect the el ectri cal connector from the
sensor (Fi g. 27).
(4) Remove the sensor mounti ng bol t (Fi g. 27).
(5) Pul l the sensor from the speedometer pi ni on
gear adapter for removal .
INSTALLATION
(1) I nstal l new sensor i nto speedometer gear
adapter.
(2) Ti ghten sensor mounti ng bol t. To prevent dam-
age to sensor or speedometer adapter, be sure the
sensor i s mounted fl ush to the adapter before ti ght-
eni ng.
(3) Connect el ectri cal connector to sensor.
SPECIFICATIONS
GLOW PLUG CURRENT DRAW
Initial Current Draw: Approxi matel y 2225
amps per pl ug.
After 20 seconds of operation: Approxi matel y
912 amps per pl ug.
TORQUE CHART 2. 5L DIESEL
Fig. 27 Sensor Removal/InstallationTypical
14 - 40 FUEL SYSTEM 2. 5L DIESEL ENGINE ZG
REMOVAL AND INSTALLATION (Continued)
STEERING
CONTENTS
page page
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 9
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 4
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . 1
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 21
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 25
POWER STEERING
INDEX
page page
GENERAL INFORMATION
POWER STEERING SYSTEM . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM DIAGNOSIS
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
POWER STEERING SYSTEM
The power steeri ng pump (Fi g. 1) i s a constant
fl ow rate and di spl acement vane type pump. The
pump reservoi r i s attached to the pump body. The
pump i s connected to the steeri ng by the pressure
and return hoses.
The steeri ng gear (Fi g. 1) used i s a reci rcul ati ng
bal l type gear. The gear acts as a rol l i ng thread
between the worm shaft and rack pi ston. The worm
shaft i s supported by a thrust beari ng at the l ower
end and a beari ng assembl y at the upper end. When
the worm shaft i s turned the rack pi ston moves. The
rack pi ston teeth mesh wi th the pi tman shaft. Turn-
i ng the worm shaft turns the pi tman shaft, whi ch
moves the steeri ng l i nkage.
The power steeri ng system consi sts of:
Hydraul i c pump
Reci rcul ati ng bal l steeri ng gear
Steeri ng col umn
Steeri ng l i nkage
Fig. 1 Power Steering Gear & Pump
HYDRAULIC PUMP ASSEMBLY RETURN LINE HOSE ASSEM- BLY PRESSURE HOSE ASSEM- BLY FITTINGS STEERING GEAR ASSEMBLY
ZG STEERING 19 - 1
DIAGNOSIS AND TESTING
POWER STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i ts travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash
panel seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.
2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other
components.
5. Reposition hose.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering components
.
3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of
adjustment.
7. Repair or replace gear.
19 - 2 STEERING ZG
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5. Pressure test and repair as
necessary.
6. Internal gear leak. 6. Pressure and flow test, and repair
as necessary.
STEERING WHEEL
DOES NOT WANT TO RETURN TO
CENTER POSITION
1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust as necessary.
LOOSE STEERING AND VEHICLE LEAD
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE PLAY IN STEERING
WHEEL
1. Worn or loose suspension or
steering components.
1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Inspect and replace as
necessary.
VEHICLE PULLS OR LEADS TO
ONE SIDE.
1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
ZG STEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)
POWER STEERING PUMP
INDEX
page page
DESCRIPTION AND OPERATION
POWER STEERING PUMP . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING
POWER STEERING PUMP . . . . . . . . . . . . . . . . 4
PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
POWER STEERING PUMPINITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
POWER STEERING PUMP 5.2L/5.9L . . . . . . . 6
POWER STEERING PUMP 4.0L . . . . . . . . . . . . 6
DISASSEMBLY AND ASSEMBLY
PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . 7
TC-SERIES PUMP RESERVOIR . . . . . . . . . . . . . 7
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . . . 8
DESCRIPTION AND OPERATION
POWER STEERING PUMP
Hydraul i c pressure i s provi ded for operati on of the
power steeri ng gear by a bel t dri ven power steeri ng
pump. The power steeri ng pump i s a constant fl ow
rate and di spl acement, vane-type pump. The i nternal
parts i n the housi ng operate submerged i n fl ui d. The
fl ow control ori fi ce i s part of the hi gh pressure l i ne
fi tti ng. The pressure rel i ef val ve i nsi de the fl ow con-
trol val ve l i mi ts the pump pressure. The reservoi r i s
attached to the pump body wi th spri ng cl i ps (Fi g. 1).
The power steeri ng pump i s connected to the steer-
i ng gear by the pressure and return hoses. The pump
shaft has a pressed-on dri ve pul l ey that i s bel t dri ven
by the crankshaft pul l ey (Fi g. 1).
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
DIAGNOSIS AND TESTING
POWER STEERING PUMP
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the fl ow rate of the power steeri ng
pump al ong wi th the maxi mum rel i ef pressure. Per-
form test any ti me a power steeri ng system probl em
i s present. Thi s test wi l l determi ne i f the power
steeri ng pump or power steeri ng gear i s not functi on-
i ng properl y. The fol l owi ng pressure and fl ow test i s
performed usi ng Power Steeri ng Anal yzer Tool ki t
6815 (Fi g. 2) and Adapter Ki t 6893.
POWER STEERING PUMP PRESSURE TEST
(1) Check bel t tensi on and adjust as necessary.
(2) Di sconnect hi gh pressure hose at gear or pump.
Use a contai ner for dri ppi ng fl ui d.
(3) Connect pressure gauge from Power Steeri ng
Anal yzer Tool ki t 6815 to both hoses usi ng appropri -
ate adapter from Adapter Ki t 6893. Connect spare
pressure hose to gear or pump.
(4) Open the test val ve compl etel y.
(5) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge and to get ai r out of the fl ui d. Then shut off
engi ne.
Fig. 1 TC Series Pump With Integral Reservoir
CAP FLUID RESER- VOIR (TYPICAL) HIGH-PRESSURE FITTING DRIVE PULLEY PUMP BODY RESERVOIRCLIP
19 - 4 STEERING ZG
(6) Check fl ui d l evel , add fl ui d as necessary. Start
engi ne agai n and l et i dl e.
(7) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than three seconds as the pump could be
damaged.
(8) Cl ose val ve ful l y three ti mes and record hi gh-
est pressure i ndi cated each ti me. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
NOTE: Refer to pump relief pressure chart.
CAUTION: Do not force the pump to operate
against the stops for more than 2 to 3 seconds at a
time because, pump damage will result.
(9) Open the test val ve, turn steeri ng wheel
extreme l eft and ri ght posi ti ons agai nst the stops.
Record the hi ghest i ndi cated pressure at each posi -
ti on. Compare readi ngs to speci fi cati ons. I f hi ghest
output pressures are not the same agai nst ei ther
stop, the gear i s l eaki ng i nternal l y and must be
repai red.
PUMP LEAKAGE DIAGNOSIS
SERVICE PROCEDURES
POWER STEERING PUMPINITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two (2) mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
Fig. 2 Pressure Test Gauge
ADAPTER FIT- TINGS SPECIAL TOOL 6815
PUMP RELIEF PRESSURE CHART
ENGINE RELIEF PRESSURE 50
4.0L 9653 kPa (1400 psi)
5.2L 9653 kPa (1400 psi)
5.9L 9653 kPa (1400 psi)
1. BUSHING (BEARING) WORN, SEAL WORN. REPLACE PUMP. 2. REPLACE RESERVOIR O-RING SEAL. 3. TORQUE HOSE FITTING NUT TO SPECIFICATIONS. IF LEAKAGE PERSISTS, REPLACE O-RING SEAL. 4. TORQUE FITTING TO SPECIFICATIONS. IF LEAKAGE PERSISTS, REPLACE O-RING SEAL. 5. REPLACE PUMP. 6. CHECK OIL LEVEL: IF LEAKAGE PERSISTS WITH THE LEVEL CORRECT AND CAP TIGHT, REPLACE THE CAP.
ZG STEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
REMOVAL AND INSTALLATION
POWER STEERING PUMP 4. 0L
REMOVAL
(1) Remove serpenti ne dri ve bel t, refer to Group 7
Cool i ng.
(2) Vehi cl es equi pped wi th Speed Proporti onal
Steeri ng, di sconnect actuator harness.
(3) Remove pressure and return hoses from pump
and drai n pump.
(4) Remove 3 pump mounti ng bol ts through pul l ey
access hol es.
(5) Loosen the 3 pump bracket bol ts (Fi g. 3).
(6) Ti l t pump downward and remove from engi ne.
(7) Remove pul l ey from pump.
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) I nstal l pump on engi ne.
(3) Ti ghten pump bracket bol ts to 47 Nm (35 ft.
l bs.).
(4) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 Nm (20 ft. l bs.).
(5) I nstal l the pressure and return hoses to pump.
(6) Vehi cl es equi pped wi th Speed Pro Steeri ng,
connect actuator harness.
(7) I nstal l dri ve bel t, refer to Group 7 Cool i ng.
(8) Add power steeri ng fl ui d. Refer to Power Steer-
i ng Pump I ni ti al Operati on i n thi s secti on.
POWER STEERING PUMP 5. 2L/5. 9L
REMOVAL
(1) Remove the serpenti ne dri ve bel t. Refer to
Group 7 Cool i ng.
(2) Remove the pressure and return hoses from
pump and drai n pump.
(3) Vehi cl es equi pped wi th Speed Proporti onal
Steeri ng, di sconnect actuator harness.
(4) Remove pump mounti ng bol ts and remove the
pump (Fi g. 4).
(5) Remove pul l ey from pump.
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) Mount pump on bracket and i nstal l bol ts.
Ti ghten bol ts to 27 Nm (20 ft. l bs.).
(3) I nstal l the pressure and return hoses to pump.
Fig. 3 Pump Mounting 4.0L
PUMP ASSEMBLY PUMP BRACKET
19 - 6 STEERING ZG
SERVICE PROCEDURES (Continued)
(4) Vehi cl es equi pped wi th Speed Pro Steeri ng,
connect actuator harness.
(5) I nstal l dri ve bel t, refer to Group 7 Cool i ng.
(6) Add power steeri ng fl ui d. Refer to Power Steer-
i ng Pump I ni ti al Operati on i n thi s secti on.
DISASSEMBLY AND ASSEMBLY
PUMP PULLEY
DISASSEMBLY
(1) Remove pump assembl y.
(2) Remove pul l ey from pump wi th Pul l er C-4333
(Fi g. 5).
ASSEMBLY
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
(Fi g. 6) fl ush wi th the end of the shaft. Ensure the
tool and pul l ey remai n al i gned wi th the pump shaft.
(3) I nstal l pump assembl y.
(4) Wi th Serpenti ne Bel ts; Run engi ne unti l warm
(5 mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
TC-SERIES PUMP RESERVOIR
DISASSEMBLY
(1) Remove power steeri ng pump.
(2) Cl ean exteri or of pump.
(3) Cl amp the pump body i n a soft jaw vi ce.
(4) Pry up tab and sl i de the retai ni ng cl i ps off (Fi g.
7).
Fig. 4 Pump Mounting 5.2L/59L
PUMP PUMP BRACKET
Fig. 5 Pulley Removal
POWER STEERING PUMP DRIVE PULLEY SPECIAL TOOL C-4333
Fig. 6 Pulley Installation
POWER STEERING PUMP DRIVE PULLEY SPECIAL TOOL C-4063B
Fig. 7 Pump Reservoir Clips
RESERVOIR RETAINING CLIPS
ZG STEERING 19 - 7
REMOVAL AND INSTALLATION (Continued)
(5) Remove fl ui d reservoi r from pump body.
Remove and di scard O-ri ng seal .
ASSEMBLY
(1) Lubri cate new O-ri ng Seal wi th Mopar Power
Steeri ng Fl ui d or equi val ent.
(2) I nstal l O-ri ng seal i n housi ng.
(3) I nstal l reservoi r onto housi ng.
(4) Sl i de and tap i n reservoi r retai ner cl i ps unti l
tab l ocks to housi ng.
(5) I nstal l power steeri ng pump. Refer to Pump
Repl acement i n thi s secti on.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Pump
Bracket Bol ts . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Pump Bol ts . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Fl ow Control Val ve . . . . . . . . . 75 Nm (55 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . 28 Nm (21 ft. l bs.)
SPECIAL TOOLS
POWER STEERING PUMP
Installer, Power Steering PulleyC-4063B
Analyzer Set, Power Steering Flow/Pressure6815
Adapters, Power Steering Flow/PressureTester 6893
Puller C-4333
19 - 8 STEERING ZG
DISASSEMBLY AND ASSEMBLY (Continued)
POWER STEERING GEAR
INDEX
page page
DESCRIPTION AND OPERATION
POWER STEERING GEAR . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING
POWER STEERING GEAR LEAKAGE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL AND INSTALLATION
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . 11
DISASSEMBLY AND ASSEMBLY
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . 12
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . 12
RACK PISTON AND WORM SHAFT . . . . . . . . . 16
SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 13
ADJUSTMENTS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
POWER STEERING GEAR . . . . . . . . . . . . . . . . 20
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIAL TOOLS
POWER STEERING GEAR . . . . . . . . . . . . . . . . 20
DESCRIPTION AND OPERATION
POWER STEERING GEAR
The power steeri ng gear i s a reci rcul ati ng bal l type
gear (Fi g. 1). The gear acts as a rol l i ng thread
between the worm shaft and rack pi ston. The worm
shaft i s supported by a thrust beari ng at the l ower
end and a beari ng assembl y at the upper end. When
the worm shaft i s turned the rack pi ston moves. The
rack pi ston teeth mesh wi th the pi tman shaft. Turn-
i ng the worm shaft turns the pi tman shaft, whi ch
turns the steeri ng l i nkage.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
ZG STEERING 19 - 9
Fig. 1 Recirculating Ball Type Gear
RING, RETAINING PLUG SEAL, O-RING RING, TEFLON COVER, SIDE NUT, ADJUSTER LOCK GASKET SHAFT, PITMAN SHAFT, WORM RACE BEARING, THRUST VALVE, CHECK HOUSING SCREW CLAMP GUIDE, BALL BALLS PISTON, RACK PLUG BEARING, NEEDLE WASHER, BACKUP RING, RETAINING SHAFT, STUB SPOOL, VALVE BODY, VALVE NUT, COUPLING SHIELD RET. AND LOCK THRUST SUPPORT ASSEM- BLY SEAL, PITMAN SHAFT SEAL, DUST NUT, ADJUSTER
19 - 10 STEERING ZG
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
POWER STEERING GEAR LEAKAGE DIAGNOSIS
REMOVAL AND INSTALLATION
STEERING GEAR
REMOVAL
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on wi th the steeri ng wheel centered.
(2) Remove and cap the pressure and return hoses
from the steeri ng gear.
(3) Remove the col umn coupl er shaft from the gear
(Fi g. 2).
(4) Remove pi tman arm from gear wi th Pul l er
C-4150A (Fi g. 3).
(5) Remove the steeri ng gear retai ni ng bol ts and
nuts. Remove the steeri ng gear from the vehi cl e (Fi g.
4).
INSTALLATION
(1) Posi ti on the steeri ng gear on the frame rai l and
i nstal l the bol ts. Ti ghten the bol ts to 88 Nm (65 ft.
l bs.) torque.
(2) I nstal l the col umn coupl er shaft.
(3) I nstal l the pi tman arm and ti ghten nut to 251
Nm (185 ft. l bs.).
(4) Connect pressure and return hoses to steeri ng
gear and ti ghten to 28 Nm (21 ft. l bs.).
Fig. 2 Coupling Shaft
DASH PANEL COUPLER SHAFT BOLT GEAR BOLT COLUMN 1. SIDE COVER LEAK TORQUE SIDE COVER BOLTS TO SPECIFICATION. REPLACE THE SIDE COVER SEAL IF THE LEAKAGE PERSISTS. 2. ADJUSTER PLUG SEAL REPLACE THE ADJUSTER PLUG SEALS. 3. PRESSURE LINE FITTING TORQUE THE HOSE FITTING NUT TO SPECIFICA- TIONS. IF LEAKAGE PERSISTS, REPLACE THE SEAL. 4. PITMAN SHAFT SEALS REPLACE THE SEALS. 5. TOP COVER SEAL REPLACE THE SEAL.
Fig. 3 Pitman Arm Removal
SPECIAL TOOL C-4150A WRENCH PITMAN ARM
Fig. 4 Steering Gear Mounting
SCREW NUT PITMAN ARM STEERING GEAR FRAME RAIL
ZG STEERING 19 - 11
DISASSEMBLY AND ASSEMBLY
HOUSING END PLUG
DISASSEMBLY
(1) Unseat and remove retai ni ng ri ng from groove
wi th a punch through the hol e i n the end of the
housi ng (Fi g. 5).
(2) Rotate stub shaft sl owl y COUNTER-CLOCK-
WI SE to force the end pl ug out from housi ng.
CAUTION: Do not turn stub shaft any further than
necessary. The rack piston balls will drop out of the
rack piston circuit if the stub shaft is turned too far.
(3) Remove O-ri ng from the housi ng (Fi g. 6).
ASSEMBLY
(1) Lubri cate O-ri ng wi th power steeri ng fl ui d and
i nstal l i nto the housi ng.
(2) I nstal l end pl ug by tappi ng the pl ug l i ghtl y
wi th a pl asti c mal l et i nto the housi ng.
(3) I nstal l retai ni ng ri ng so one end of the ri ng
covers the housi ng access hol e (Fi g. 7).
PITMAN SHAFT/SEALS/BEARING
DISASSEMBLY
(1) Cl ean exposed end of pi tman shaft and housi ng
wi th a wi re brush.
(2) Remove prel oad adjuster nut (Fi g. 8).
(3) Rotate stub shaft to center the gear.
(4) Remove si de cover bol ts and remove si de cover,
gasket and pi tman shaft as an assembl y (Fi g. 8).
(5) Remove pi tman shaft from the si de cover.
(6) Remove dust seal from the housi ng wi th a seal
pi ck (Fi g. 9).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(7) Remove retai ni ng ri ng wi th snap ri ng pl i ers.
(8) Remove washer from the housi ng.
(9) Remove oi l seal from the housi ng wi th a seal
pi ck.
(10) Remove pi tman shaft beari ng from housi ng
wi th a beari ng dri ver and handl e (Fi g. 10).
ASSEMBLY
(1) I nstal l pi tman shaft beari ng i nto housi ng wi th
a beari ng dri ver and handl e.
Fig. 5 End Plug Retaining Ring
RETAINING RING
Fig. 6 End Plug Components
HOUSING ASSEMBLY HOUSING END PLUG O-RING SEAL HOUSING END PLUG RETAINING RING
Fig. 7 Installing The Retaining Ring
RING CAP PUNCH ACCESS HOLE RETAINERRING
19 - 12 STEERING ZG
(2) Coat the oi l seal s and washer wi th grease.
(3) I nstal l the oi l seal wi th a dri ver and handl e.
(4) I nstal l backup washer.
(5) I nstal l the retai ner ri ng wi th snap ri ng pl i ers.
(6) I nstal l dust seal wi th a dri ver and handl e.
(7) I nstal l pi tman shaft to si de cover by screwi ng
shaft i n unti l i t ful l y seats to si de cover.
(8) I nstal l prel oad adjuster nut. Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(9) I nstal l gasket to si de cover and bend tabs
around edges of si de cover.
(10) I nstal l pi tman shaft assembl y and si de cover
to housi ng.
(11) I nstal l si de cover bol ts and ti ghten to 60 Nm
(44 ft. l bs.).
(12) Adjust Over-Center Rotati on Torque.
SPOOL VALVE
DISASSEMBLY
(1) Remove l ock nut (Fi g. 11) and.
Fig. 8 Side Cover and Pitman Shaft
SIDE COVER BOLTS
PRELOAD ADJUSTER NUT
SIDE COVER
Fig. 9 Pitman Shaft Seals & Bearing
BEARING
WASHER
DUST SEAL
Fig. 10 Needle Bearing Removal
REMOVER SIDE COVER AREA
Fig. 11
ADJUSTER NUT
STEERING GEAR
LOCK NUT
ZG STEERING 19 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove adjuster nut wi th Spanner Wrench
C-4381.
(3) Remove thrust support assembl y out of the
housi ng (Fi g. 12).
(4) Pul l stub shaft and val ve assembl y from the
housi ng (Fi g. 13).
(5) Remove stub shaft from val ve assembl y by
l i ghtl y tappi ng on a bl ock of wood to l oosen shaft.
Then di sengage stub shaft pi n from hol e i n spool
val ve and separate the val ve assembl y from stub
shaft (Fi g. 14).
(6) Remove spool val ve from val ve body by pul l i ng
and rotati ng the spool val ve from the val ve body (Fi g.
15).
(7) Remove spool val ve O-ri ng and val ve body
tefl on ri ngs and O-ri ngs underneath the tefl on ri ngs
(Fi g. 16).
(8) Remove the O-ri ng between the worm shaft
and the stub shaft.
ASSEMBLY
NOTE: Clean and dry all components, then lubri-
cate with power steering fluid.
(1) I nstal l spool val ve spool O-ri ng.
(2) I nstal l spool val ve i n val ve body by pushi ng
and rotati ng. Hol e i n spool val ve for stub shaft pi n
must be accessi bl e from opposi te end of val ve body.
(3) I nstal l stub shaft i n val ve spool and engage
l ocati ng pi n on stub shaft i nto spool val ve hol e (Fi g.
17).
NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoul-
der.
Fig. 12 Thrust Support Assembly
STUB SHAFT
HOUSING
THRUST SUPPORT ASSEM- BLY
Fig. 13 Valve Assembly With Stub Shaft
GEAR
THRUST SUPPORT
LOCK NUT
Fig. 14 Stub Shaft
STUBSHAFT VALVE BODY HOLE IN SPOOL SHAFT PIN 6mm (1/4)
Fig. 15 Spool Valve
SPOOL VALVE ROTATE VALVE TO REMOVE VALVE BODY
19 - 14 STEERING ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(4) I nstal l O-ri ngs and tefl on ri ngs over the
O-ri ngs on val ve body.
(5) I nstal l O-ri ng i nto the back of the stub shaft
(Fi g. 18).
(6) I nstal l stub shaft and val ve assembl y i n the
housi ng. Li ne up worm shaft to sl ots i n the val ve
assembl y.
(7) I nstal l thrust support assembl y.
NOTE: If any component of the thrust support
assembly are damaged (Fig. 19) the assembly must
be replaced.
(8) I nstal l adjuster nut and l ock nut.
(9) Adjust Thrust Beari ng Prel oad and Over-Cen-
ter Rotati ng Torque.
Fig. 16 Valve Seals
O-RING SEALS
Fig. 17 Stub Shaft Installation
NOTCH IN CAP VALVE BODY PIN
Fig. 18 Stub Shaft O-Ring
SPOOL VALVE BODY
STUB SHAFT
O-RING
Fig. 19 Thrust Support Assembly
SEAL
SUPPORT
O-RING
ZG STEERING 19 - 15
DISASSEMBLY AND ASSEMBLY (Continued)
RACK PISTON AND WORM SHAFT
DISASSEMBLY
(1) Remove si de cover and pi tman shaft.
(2) Remove housi ng end pl ug.
(3) Remove rack pi ston pl ug (Fi g. 20).
(4) Turn stub shaft COUNTERCLOCKWI SE unti l
the rack pi ston begi ns to come out of the housi ng.
(5) I nsert Arbor C-4175 i nto bore of rack pi ston
(Fi g. 21) and hol d tool ti ghtl y agai nst worm shaft.
(6) Turn the stub shaft COUNTERCLOCKWI SE,
thi s wi l l force the rack pi ston onto the tool and hol d
the rack pi ston bal l s i n pl ace.
(7) Remove the rack pi ston and tool together from
housi ng.
(8) Remove tool from rack pi ston.
(9) Remove rack pi ston bal l s.
(10) Remove cl amp bol ts, cl amp and bal l gui de
(Fi g. 22).
(11) Remove tefl on ri ng and O-ri ng from the rack
pi ston (Fi g. 23).
(12) Remove the adjuster l ock nut and adjuster
nut.
(13) Pul l the stub shaft wi th the spool val ve and
thrust support assembl y out of the housi ng.
(14) Remove the worm shaft from the housi ng
(Fi g. 24).
ASSEMBLY
NOTE: Clean and dry all components and lubricate
with power steering fluid.
Fig. 20 Rack Piston End Plug
EXTENSION END PLUG RACK PISTON RATCHET
Fig. 21 Rack Piston with Arbor
RACK PISTON SPECIAL TOOL C-4175
Fig. 22 Rack Piston
CLAMP
BALLS
RACK PISTON
Fig. 23 Rack Piston Teflon Ring and O-Ring
TEFLON SEAL BACK-UP O-RING MUST BE INSTALLED UNDER PISTON RING RACK PISTON NUT
19 - 16 STEERING ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(1) Check for scores, ni cks or burrs on the rack
pi ston fi ni shed surface. Sl i ght wear i s normal on the
worm gear surfaces.
(2) I nstal l O-ri ng and tefl on ri ng on the rack pi s-
ton.
(3) I nstal l worm shaft i n the rack pi ston and al i gn
worm shaft spi ral groove wi th rack pi ston bal l gui de
hol e (Fi g. 25).
CAUTION: The rack piston balls must be installed
alternately into the rack piston and ball guide. This
maintains worm shaft preload. There are 12 black
balls and 12 silver (Chrome) balls. The black balls
are smaller than the silver balls.
(4) Lubri cate and i nstal l rack pi ston bal l s through
return gui de hol e whi l e turni ng worm shaft COUN-
TERCLOCKWI SE (Fi g. 25).
(5) I nstal l remai ni ng bal l s i n gui de usi ng grease to
hol d the bal l s i n pl ace (Fi g. 26).
(6) I nstal l the gui de onto rack pi ston and i nstal l
cl amp and cl amp bol ts. Ti ghten bol ts to 58 Nm (43
ft. l bs.).
(7) I nsert Arbor C-4175 i nto bore of rack pi ston
and hol d tool ti ghtl y agai nst worm shaft.
(8) Turn the worm shaft COUNTERCLOCKWI SE
whi l e pushi ng on the arbor. Thi s wi l l force the rack
pi ston onto the arbor and hol d the rack pi ston bal l s
i n pl ace.
(9) I nstal l the races and thrust beari ng on the
worm shaft and i nstal l shaft i n the housi ng (Fi g. 24).
(10) I nstal l the stub shaft wi th spool val ve, thrust
support assembl y and adjuster nut i n the housi ng.
(11) I nstal l the rack pi ston and arbor tool i nto the
housi ng.
(12) Hol d arbor ti ghtl y agai nst worm shaft and
turn stub shaft CLOCKWI SE unti l rack pi ston i s
seated on worm shaft.
(13) I nstal l pi tman shaft and si de cover i n the
housi ng.
(14) I nstal l rack pi ston pl ug and ti ghten to 150
Nm (111 ft. l bs.).
(15) I nstal l housi ng end pl ug.
(16) Adjust worm shaft thrust beari ng prel oad and
over-center rotati ng torque.
Fig. 24 Worm Shaft
GEAR HOUSING
BEARING RACE
WORM SHAFT
Fig. 25 Installing Balls in Rack Piston
INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING WORM COUNTER CLOCKWISE WORM FLANGE
Fig. 26 Balls in the Return Guide
GUIDE PETROLEUM JELLY BALLS
ZG STEERING 19 - 17
DISASSEMBLY AND ASSEMBLY (Continued)
ADJ USTMENTS
STEERING GEAR
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
WORM THRUST BEARING PRELOAD
(1) Remove adjuster pl ug l ocknut (Fi g. 27).
(2) Rotate the stub shaft back and forth to drai n
the remai ni ng fl ui d.
(3) Turn the adjuster i n wi th Spanner Wrench
C-4381. Ti ghten the pl ug and thrust beari ng i n the
housi ng unti l fi rml y bottomed i n housi ng.
(4) Pl ace an i ndex mark on the housi ng even wi th
one of the hol es i n adjuster pl ug (Fi g. 28).
(5) Measure back (countercl ockwi se) 13 mm (0.50
i n) and mark housi ng (Fi g. 29).
(6) Rotate adjustment cap back (countercl ockwi se)
wi th spanner wrench unti l hol e i s al i gned wi th the
second mark (Fi g. 30).
(7) I nstal l and ti ghten l ocknut to 108 Nm (80 ft.
l bs.). Be sure adjustment cap does not turn whi l e
ti ghteni ng the l ocknut.
OVER-CENTER ROTATION TORQUE
(1) Rotate the stub shaft back and forth to drai n
the remai ni ng fl ui d.
(2) Rotate the stub shaft from stop to stop and
count the number of turns.
(3) Starti ng at ei ther stop turn the stub shaft back
1/2 the total number of turns. Thi s i s the center of
the gear travel (Fi g. 31).
(4) Turn the pi tman shaft adjuster screw back
(COUNTERCLOCKWI SE) unti l ful l y extended, then
turn back i n (CLOCKWI SE) one ful l turn.
Fig. 27 Loosening the Adjuster Plug
PUNCH LOCK NUT STUB SHAFT
Fig. 28 Alignment Marking On Housing
INDEX
Fig. 29 Second Marking On Housing
REFER- ENCE MARK
19 - 18 STEERING ZG
(5) Pl ace the torque wrench i n the verti cal posi ti on
on the stub shaft. Rotate the wrench 45 degrees each
si de of the center and record the hi ghest rotati onal
torque on center (Fi g. 32).
NOTE: The stub shaft must rotate smoothly without
not sticking or binding.
(6) The recorded beari ng prel oad shoul d be 0.7-1.7
Nm (6-15 i n. l bs.). I f the torque i s outsi de thi s range,
the gear shoul d be readjusted.
(7) I f an adjustment i s necessary, turn the pi tman
shaft adjuster screw to obtai n the correct prel oad 0.7-
1.7 Nm (6-15 i n. l bs.).
NOTE: To increase the preload turn the screw
CLOCKWISE.
(8) Prevent the adjuster screw from turni ng whi l e
ti ghteni ng adjuster l ock nut. Ti ghten the adjuster
l ock nut to 49 Nm (36 ft. l bs.).
Fig. 30 Aligning To The Second Mark
FIRST MARK SECOND MARK SPANNER WRENCH
Fig. 31 Steering Gear Centered
ADJUSTMENT SCREW MASTER SPLINE
Fig. 32 Checking Over-Center Rotation Torque
CENTER
ZG STEERING 19 - 19
ADJ USTMENTS (Continued)
SPECIFICATIONS
POWER STEERING GEAR
Steering Gear
Type . . . . . . . . . . . . . . . . . . . . . Reci rcul ati ng Bal l
Gear Rati o . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7:1
WormShaft Bearing
Prel oad . . . . . . . . . . . 0.45-1.13 Nm (4-10 i n. l bs.)
Pitman Shaft Overcenter Drag
New Gear (under 400 mi l es) . 0.45-0.90 Nm (4-8 i n.
l bs.) + Worm Shaft Prel oad
Used Gear (over 400 mi l es) . 0.5-0.6 Nm (4-5 i n. l bs.)
+ Worm Shaft Prel oad
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Gear
Adjustment Cap Locknut . . . . 108 Nm (80 ft. l bs.)
Adjustment Screw Locknut . . . 49 Nm (36 ft. l bs.)
Gear to Frame Bol ts . . . . . . . . 88 Nm (65 ft. l bs.)
Pi tman Shaft Nut . . . . . . . . 251 Nm (185 ft. l bs.)
Rack Pi ston Pl ug . . . . . . . . . 150 Nm (111 ft. l bs.)
Si de Cover Bol ts . . . . . . . . . . . 60 Nm (44 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . 28 Nm (21 ft. l bs.)
Return Li ne . . . . . . . . . . . . . . . 28 Nm (21 ft. l bs.)
Return Gui de Cl amp Bol t . . . . 58 Nm (43 ft. l bs.)
SPECIAL TOOLS
POWER STEERING GEAR
Remover/Installer, Steering PlugC-4381
Remover, Pitman Arm C-4150A
Remover/Installer Steering Rack PistonC-4175
19 - 20 STEERING ZG
STEERING COLUMN
INDEX
page page
GENERAL INFORMATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL AND INSTALLATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 24
GENERAL INFORMATION
STEERING COLUMN
The ti l t col umn (Fi g. 1) has been desi gned to be
servi ced as an assembl y; l ess wi ri ng, swi tches,
shrouds, steeri ng wheel , etc. Most steeri ng col umn
components can be servi ced wi thout removi ng the
steeri ng col umn from the vehi cl e.
SERVICE PRECAUTIONS
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to Group 8 M and fol l ow al l WARNI NGS and
CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIRBAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIRBAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
Fig. 1 Steering Column
TILT LEVER
UPPER SHROUD
PANEL BRACKET
ZG STEERING 19 - 21
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Do not
remove ignition locking link, shaft lock plate or
plate retainer. This will damage the column (Fig. 2)
and (Fig. 3).
DIAGNOSIS AND TESTING
IGNITION SWITCH
TEST AND REPAIR
I f the i gni ti on swi tch effort i s excessi ve, remove the
i gni ti on swi tch from the steeri ng col umn. Refer to
Group 8D I gni ti on System. Usi ng a key cyl i nder,
check the turni ng effort of the swi tch. I f the i gni ti on
swi tch bi nds l ook for the fol l owi ng condi ti ons.
(1) Look for rough areas or fl ash i n the casti ng
and i f found remove wi th a fi l e (Fi g. 4).
(2) Remove the l i nk and sl i der and check the l i nk
to see i f i t i s bent. I f so repl ace wi th a new part.
(3) Put the sl i der i n i ts sl ot i n the sl eeve and ver-
i fy a l oose fi t over the l ength of the sl ot. I f the sl i der
bi nds i n the sl ot at any poi nt l i ghtl y fi l e the sl i der
unti l cl earance i s achi eved.
(4) I f no bi ndi ng i s found, l i ghtl y fi l e the ramp on
the i gni ti on swi tch, (The ramp fi ts i nto the casti ng)
unti l bi ndi ng no l onger occurs.
REMOVAL AND INSTALLATION
STEERING COLUMN
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. FAILURE TO DO SO MAY RESULT IN ACCI-
DENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. REFER TO GROUP
8M RESTRAINT SYSTEMS FOR SERVICE PROCE-
DURES.
REMOVAL
(1) Posi ti on front wheel s strai ght ahead.
(2) Di sconnect the negati ve (ground) cabl e from
the battery.
(3) Remove ai rbag, steeri ng wheel and cl ockspri ng.
Refer to Group 8M Passi ve Restrai nt Systems for
servi ce procedures.
(4) Remove col umn coupl er upper pi nch bol t (Fi g.
5).
(5) Remove the tri m panel col umn cover and sup-
port pl ate (Fi g. 6).
(6) Remove ti l t l ever from col umn.
(7) Remove the upper and l ower l ock housi ng
shrouds.
(8) Remove the heater cross over tube from under
the col umn.
(9) Loosen the panel bracket nuts/studs to al l ow
the col umn to drop.
Fig. 2 Observe Cautions
CAUTION: DO NOT REMOVE IGNITION LOCKING LINK CAUTION: NEVER REMOVE SHAFT LOCK PLATE
Fig. 3 Observe Cautions
CAUTION: NEVER REMOVE SHAFT LOCK PLATE RETAINER
Fig. 4 Steering Column Flash Removal AndNon-
Serviceable Components
CAUTION: DO NOT REMOVE IGNITION LOCKING LINK FILE THIS AREA TO REMOVE FLASHING AND PROVIDE CLEARANCE TO ELIMINATE BINDING CAUTION: NEVER REMOVE SHAFT LOCK PLATE
19 - 22 STEERING ZG
GENERAL INFORMATION (Continued)
(10) Remove the I nterl ock cabl e from the steeri ng
col umn. Refer to Group 21 Transmi ssi on and Trans-
fer Case.
(11) Remove mul ti -functi on swi tch tamper proof
mounti ng screws and connector screw. Connector
screw wi l l stay i n the connector.
(12) Remove the wi ri ng harness from the remai n-
i ng swi tches and the steeri ng col umn (Fi g. 7).
(13) Remove the i gni ti on swi tch.
(14) Remove the toe pl ate to dash panel nuts.
(15) Remove the panel bracket nuts/studs and
remove the col umn.
INSTALLATION
(1) Wi th the front wheel s i n the strai ght ahead
posi ti on. Al i gn and i nstal l the col umn to coupl er. Do
not apply force at the top of the steering col-
umn shaft.
(2) Remove the col umn shaft shi ppi ng l ock pi n
(i nstal l ed i n servi ce col umn).
(3) Ensure the ground cl i p i s on spacer sl ot (Fi g.
8).
(4) I nstal l the I nterl ock cabl e from the steeri ng
col umn. Refer to Group 21 Transmi ssi on and Trans-
fer Case.
Fig. 6 Trim Panel Column Cover
KNEE BLOCKER TRIM PANEL
Fig. 7 Steering Column Wiring Harness
AIR BAG SQUIB WIRE CLIP SCREW MULTI-FUNCTION SWITCH CONNEC- TOR VIEW IN DIRECTION OF
ARROW Z
TO CLOCK SPRING TO KEY SWITCH TO KEYLIGHT SWITCH BEYOND THIS POINT SEE VIEW Z CLIP TROUGH AIR BAG SQUIB WIRE CLIP VIEW IN DIRECTION OF
ARROW Y
CONNECTOR
Fig. 5 Column Coupler Shaft
TOE PLATE
DASH PANEL
SHAFT
ZG STEERING 19 - 23
REMOVAL AND INSTALLATION (Continued)
(5) I nstal l wi ri ng harness connecti ons to steeri ng
col umn. Ensure the wiring is not pinched and
all connections are correctly locked in place.
(6) I nstal l the mul ti -functi on swi tch wi th the
tamper proof mounti ng screws and i nstal l harness
connector wi th screw.
(7) I nstal l the i gni ti on swi tch.
(8) I nstal l shaft coupl er pi nch bol t l oose, l oad col -
umn up to panel bracket.
(9) Be sure both spacers are ful l y seated i n the col -
umn support bracket. Ti ghten the col umn panel
bracket support nuts/studs to 12 Nm (105 i n. l bs.).
Ensure the nut is installed on the SHORT
threaded side of the stud.
(10) Ti ghten the toe pl ate attachi ng nuts to 12
Nm (105 i n. l bs.).
(11) Ti ghten the coupl er pi nch bol t to 49 Nm (36
ft. l bs.).
(12) I nstal l the heater cross over tube under the
col umn.
(13) I nstal l the upper and l ower shrouds and ti l t
l ever.
(14) I nstal l the tri m panel col umn cover and sup-
port pl ate.
(15) I nstal l the cl ockspri ng, steeri ng wheel and
ai rbag, refer to Group 8M Passi ve Restrai nt Sys-
tems for procedures.
(16) Connect the battery ground (negati ve) cabl e.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Steering Column
Steeri ng Wheel Nut . . . . . . . . 61 Nm (45 ft. l bs.)
Col umn Bracket Nuts . . . . . 12 Nm (105 i n. l bs.)
Shaft Coupl er Bol ts . . . . . . . . 49 Nm (36 ft. l bs.)
Toe Pl ate Bol ts . . . . . . . . . . 12 Nm (105 i n. l bs.)
Fig. 8 Ground Clip & Spacer
GROUND CLIP PLASTIC CAPSULE (SPAC- ER) JACKET COLUMN BRACKET WASHER NUT
19 - 24 STEERING ZG
REMOVAL AND INSTALLATION (Continued)
STEERING LINKAGE
INDEX
page page
GENERAL INFORMATION
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . 25
SERVICE PROCEDURES
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STEERING DAMPENER . . . . . . . . . . . . . . . . . . 27
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIAL TOOLS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . 27
GENERAL INFORMATION
STEERING LINKAGE
The steeri ng l i nkage consi sts of a pi tman arm,
drag l i nk, ti e rod, and steeri ng dampener (Fi g. 1) and
(Fi g. 2). Adjustment sl eeves are used on the ti e rod
and drag l i nk for toe and steeri ng wheel al i gnment.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
NOTE: Periodic lubrication of the steering system
components is required. Refer to Group 0, Lubrica-
tion And Maintenance for the recommended mainte-
nance schedule.
SERVICE PROCEDURES
STEERING LINKAGE
NOTE: If any steering components are replaced or
serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
The ti e rod end and bal l stud seal s shoul d be
i nspected duri ng al l oi l changes. I f a seal i s damaged,
i t shoul d be repl aced. Before i nstal l i ng a new seal ,
i nspect bal l stud at the throat openi ng. Check for
l ubri cant l oss, contami nati on, bal l stud wear or cor-
rosi on. I f these condi ti ons exi st, repl ace the ti e rod. A
repl acement seal can be i nstal l ed i f l ubri cant i s i n
good condi ti on. Otherwi se, a compl ete repl acement
bal l stud end shoul d be i nstal l ed.
CAUTION: Use a Puller tool C-3894-A for tie rod
removal. Failure to use this tool could damage the
ball stud and seal (Fig. 3).
Fig. 1 Steering Linkage-6 Cylinder Engine
COTTER PIN NUT DAMPENER PITMAN ARM WASHER TIE ROD DRAG LINK
Fig. 2 Steering Linkage-8 Cylinder Engine
COTTER PIN NUT DAMPENER PITMAN ARM WASHER TIE ROD DRAG LINK
ZG STEERING 19 - 25
REMOVAL AND INSTALLATION
TIE ROD
REMOVAL
(1) Remove the cotter pi ns and nuts at the steer-
i ng knuckl e and drag l i nk (Fi g. 1) and (Fi g. 2).
(2) Loosen the bal l studs wi th a pul l er tool to
remove the ti e rod.
(3) I f necessary, l oosen the end cl amp bol ts and
remove the ti e rod ends from the tube.
INSTALLATION
(1) I f necessary, i nstal l the ti e rod ends i n the
tube. Posi ti on the ti e rod cl amp (Fi g. 4) and ti ghten
to:
Drag Li nk: 49 Nm (36 ft. l bs.)
Ti e Rod-6 Cyl . Engi ne: 27 Nm (20 ft. l bs.)
Ti e Rod-8 Cyl . Engi ne: 49 Nm (36 ft. l bs.)
(2) I nstal l the ti e rod on the drag l i nk and steeri ng
knuckl e. I nstal l the retai ni ng nuts.
(3) Ti ghten the bal l stud nut on the steeri ng
knuckl e to 47 Nm (35 ft. l bs.). Ti ghten the bal l stud
nut to drag l i nk to 75 Nm (55 ft. l bs.) torque. I nstal l
new cotter pi ns and bend end 60.
PITMAN ARM
REMOVAL
(1) Remove the cotter pi n and nut from the drag
l i nk at the pi tman arm.
(2) Remove the drag l i nk bal l stud from the pi t-
man arm wi th a pul l er.
(3) Remove the nut and washer from the steeri ng
gear shaft. Mark the pi tman shaft and pi tman arm
for i nstal l ati on reference. Remove the pi tman arm
from steeri ng gear wi th Pul l er C-4150A (Fi g. 5).
INSTALLATION
(1) Al i gn and i nstal l the pi tman arm on steeri ng
gear shaft.
(2) I nstal l the washer and nut on the shaft and
ti ghten the nut to 251 Nm (185 ft. l bs.).
(3) I nstal l drag l i nk bal l stud to pi tman arm.
I nstal l nut and ti ghten to 81 Nm (60 ft. l bs.). I nstal l
a new cotter pi n.
DRAG LINK
REMOVAL
(1) Remove the cotter pi ns and nuts at the steer-
i ng knuckl e and drag l i nk (Fi g. 1).
(2) Remove the steeri ng dampener bal l stud from
the drag l i nk wi th a pul l er tool .
Fig. 3 Ball Stud Removal
CLAMP ADJUST- MENT SLEEVE PULLER TOOL C-3894A SEAL TIE-ROD END
Fig. 4 Tie Rod/Drag Link Clamp Bolt
TIE ROD CLAMPDRAG LINK CLAMPS
Fig. 5 Pitman Arm Removal
SPECIAL TOOL C-4150A WRENCH PITMAN ARM
19 - 26 STEERING ZG
(3) Remove the drag l i nk from the steeri ng
knuckl e wi th a pul l er tool . Remove the same for ti e
rod and pi tman arm.
(4) I f necessary, l oosen the end cl amp bol ts and
remove the ti e rod end from the l i nk.
INSTALLATION
(1) I nstal l the drag l i nk adjustment sl eeve and ti e
rod end. Posi ti on cl amp bol ts (Fi g. 4).
(2) Posi ti on the drag l i nk at the steeri ng l i nkage.
I nstal l the drag l i nk to the steeri ng knuckl e nut. Do
the same for the ti e rod and pi tman arm.
(3) Ti ghten the nut at the steeri ng knuckl e to 47
Nm (35 ft. l bs.). Ti ghten the pi tman nut to 81 Nm
(60 ft. l bs.) and ti e rod bal l stud nut to 47 Nm (35 ft.
l bs.). I nstal l new cotter pi ns and bend end 60.
(4) I nstal l the steeri ng dampener onto the drag
l i nk and ti ghten the nut to 74 Nm (55 ft. l bs.).
I nstal l a new cotter pi n and bend end 60.
STEERING DAMPENER
REMOVAL
(1) Pl ace the front wheel s i n a strai ght ahead posi -
ti on.
(2) Remove the steeri ng dampener retai ni ng nut
and bol t from the axl e bracket (Fi g. 1).
(3) Remove the cotter pi n and nut from the bal l
stud at the drag l i nk.
(4) Remove the steeri ng dampener bal l stud from
the drag l i nk usi ng C-3894-A pul l er.
INSTALLATION
(1) I nstal l the steeri ng dampener to the axl e
bracket and drag l i nk.
(2) I nstal l the steeri ng dampener bol t i n the axl e
bracket and ti ghten nut to 74 Nm (55 ft. l bs.).
(3) I nstal l the bal l stud nut at the drag l i nk and
ti ghten nut to 74 Nm (55 ft. l bs.). I nstal l a new cot-
ter pi n.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Pitman Arm
Shaft Nut . . . . . . . . . . . . . . 251 Nm (185 ft. l bs.)
Drag Link
Pi tman Arm Nut . . . . . . . . . . . 81 Nm (60 ft. l bs.)
Knuckl e Nut . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Cl amp Bol ts . . . . . . . . . . . . . . 49 Nm (36 ft. l bs.)
Tie Rod Ends
4.0L Cl amp Bol ts . . . . . . . . . . 27 Nm (20 ft. l bs.)
5.2L Cl amp Bol ts . . . . . . . . . . 49 Nm (36 ft. l bs.)
Tie Rod
Knuckl e Nut . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Drag Link Nut . . . . . . . . . . . . . 75 Nm (55 ft. l bs.)
Steering Damper
Frame Bol t . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Drag Li nk Nut . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
SPECIAL TOOLS
STEERING LINKAGE
Puller C-3894A
Remover Pitman C-4150A
ZG STEERING 19 - 27
REMOVAL AND INSTALLATION (Continued)
STEERING
CONTENTS
page
SPEED PROPORTIONAL STEERING . . . . . . . . . . 1
SPEED PROPORTIONAL STEERING
INDEX
page page
DESCRIPTION AND OPERATION
POWER STEERING GEAR . . . . . . . . . . . . . . . . 2
SPEED PROPORTIONAL STEERING CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPEED PROPORTIONAL STEERING
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPEED PROPORTIONAL STEERING . . . . . . . . . 1
STEERING WHEEL SPEED SENSOR . . . . . . . . 2
DIAGNOSIS AND TESTING
SPEED PROPORTIONAL STEERING . . . . . . . . . 3
REMOVAL AND INSTALLATION
SPEED PROPORTIONAL STEERING CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING WHEEL SPEED SENSOR . . . . . . . . 3
DESCRIPTION AND OPERATION
SPEED PROPORTIONAL STEERING
Speed Proporti onal Steeri ng consi st of;
Speed Proporti onal Steeri ng Control Modul e
(SPSCM)
Steeri ng Wheel Speed Sensor (SWSS)
Speed Proporti onal Steeri ng Sol enoi d (SPSS)
Speed Proporti onal Steeri ng Gear (SPSG)
Speed Proporti onal Steeri ng provi des vari abl e
power assi st based on i nputs from the Vehi cl e Speed
Sensor and Steeri ng Wheel Speed Sensor. The sen-
sors are moni tored by the Speed Proporti onal Steer-
i ng Control Modul e. The modul e control s the
operati on of the Speed Proporti onal Steeri ng Sol enoi d
whi ch regul ated power steeri ng pump fl ow rate.
When parki ng or at l ow speeds, ful l power assi st i s
provi ded. As the vehi cl e speed i ncreases pump fl ow i s
reduced. Thi s reduces the power assi st, provi di ng the
dri ver wi th a better steeri ng feel for the road and
i mproved di recti onal stabi l i ty.
The SWSS conti nual l y moni tors steeri ng wheel
assi st. When a qui ck steeri ng maneuver i s made
whi l e the system i s operati ng at reduced power
assi st, ful l assi st i s provi ded for the maneuver
i nstantl y.
ZG STEERING 19 - 1
SPEED PROPORTIONAL STEERING CONTROL
MODULE
The control modul e i s mounted to a bracket on the
passenger si de of the front cowl panel just l eft of the
steeri ng col umn (Fi g. 1). A 14-way connector i s
attached to the modul e. The modul e moni tors steer-
i ng wheel speed and vehi cl e speed to determi ne the
amount of power steeri ng assi st needed. The modul e
control s power steeri ng assi st by sendi ng a 12-vol t
duty-cycl e si gnal (pul sed on and off) to the Speed
Proporti onal Steeri ng Sol enoi d.
STEERING WHEEL SPEED SENSOR
The Steeri ng Wheel Speed Sensor i s mounted on
the steeri ng col umn shaft bel ow the cl ock spri ng (Fi g.
2). The sensor i s used to moni tor steeri ng wheel
assi st.
SPEED PROPORTIONAL STEERING SOLENOID
The sol enoi d i s mounted to the power steeri ng
pump outl et port (Fi g. 3). The sol enoi d control s pump
output vol ume by movi ng a meteri ng rod i n and out
of a fi xed ori fi ce. The SPSCM energi zes and de-ener-
gi zes the sol enoi d to move the meteri ng rod up to 250
ti mes per second. By varyi ng the ti me energi zed ver-
sus de-energi ze steeri ng pump output vol ume and
steeri ng assi st i s control l ed.
POWER STEERING GEAR
The steeri ng gear used wi th Speed Proporti onal
Steeri ng has a speci al spool val ve. The val ve provi des
i mproved response at l ower fl ow rates. The gear i s a
servi ceabl e component.
CAUTION: A Speed Proportional Steering gear
should not be interchanged with any other steering
gear.
Fig. 1 Speed Proportional Steering Control Module
Fig. 2 Steering Wheel Speed Sensor
Fig. 3 Speed Proportional Steering Solenoid
19 - 2 STEERING ZG
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
SPEED PROPORTIONAL STEERING
For di agnosi s and testi ng procedures refer to the
Chassi s Di agnosti c Manual .
REMOVAL AND INSTALLATION
STEERING WHEEL SPEED SENSOR
REMOVAL
(1) Di sconnect the negati ve (ground) cabl e from
the battery.
(2) Remove ai rbag, refer to Group 8M El ectri cal
for procedure.
(3) Remove steeri ng wheel wi th appropri ate pul l er.
(4) Remove cl ock spri ng, refer to Group 8M El ec-
tri cal for procedure.
(5) Pry sensor retai ni ng ri ng tabs up and remove
sensor (Fi g. 4).
INSTALLATION
CAUTION: Never install a used sensor. Once the
sensor has been removed it must be replace with a
new sensor.
(1) I nstal l new sensor on col umn shaft wi th a pi ece
of thi n wal l condui t 3 i nch l ong by 3/4 i nch I D. Move
turn si gnal cancel l er off to one si de and i nsure l ocat-
i ng tab i s i n the proper posi ti on and push the sensor
down on the shaft.
CAUTION: The pipe installer must only touch the
inner metal ring of the sensor and not the plastic
housing or the sensor will be damaged.
(2) I nstal l cl ock spri ng, refer to Group 8M El ectri -
cal for procedure.
(3) I nstal l steeri ng wheel .
(4) I nstal l ai rbag, refer to Group 8M El ectri cal for
procedure.
(5) Connect negati ve (ground) cabl e to the battery.
SPEED PROPORTIONAL STEERING CONTROL
MODULE
REMOVAL
(1) Unpl ug harness from control modul e, l ocated
l eft of steeri ng col umn on front cowl panel .
(2) Sl i d the modul e off mounti ng bracket (Fi g. 5).
INSTALLATION
(1) Sl i d modul e onto mounti ng bracket.
(2) Pl ug harness i nto modul e.
Fig. 4 Steering Wheel Speed Sensor
Fig. 5 Speed Proportional Steering Control Module
ZG STEERING 19 - 3
TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
42/44RE AUTOMATIC TRANSMISSION . . . . . . . 1
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . 123
NV249 TRANSFER CASE . . . . . . . . . . . . . . . . 155
42/44RE AUTOMATIC TRANSMISSION
INDEX
page page
GENERAL INFORMATION
42/44 RE TRANSMISSION . . . . . . . . . . . . . . . . . 2
ELECTRONIC LOCK-UP TORQUE
ONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 4
RECOMMENDED FLUID . . . . . . . . . . . . . . . . . . 4
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . 4
TRANSMISSION IDENTIFICATION . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
3-4 SHIFT SEQUENCE . . . . . . . . . . . . . . . . . . . 7
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONVERTER CLUTCH ENGAGEMENT . . . . . . . 7
CONVERTER DRAINBACK VALVE . . . . . . . . . . . 7
ELECTRONIC GOVERNOR . . . . . . . . . . . . . . . . 4
GOVERNOR PRESSURE CURVES . . . . . . . . . . 6
HYDRAULIC CONTROL SYSTEM . . . . . . . . . . . 6
OVERDRIVE OFF SWITCH . . . . . . . . . . . . . . . . 7
SHIFT VALVE OPERATION . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION . . . . . . . . . . . . . . . . . . . . 14
ANALYZING ROAD TEST . . . . . . . . . . . . . . . . . 10
AUTOMATIC TRANSMISSION DIAGNOSIS . . . . 8
BRAKE TRANSMISSION SHIFT INTERLOCK . . . 9
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONVERTER STALL TEST . . . . . . . . . . . . . . . . 12
DIAGNOSIS TABLES AND CHARTSRE
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 15
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 9
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . 11
OVERDRIVE ELECTRICAL CONTROLS . . . . . . . 9
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 9
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . . . 8
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . 10
STALL TEST ANALYSIS . . . . . . . . . . . . . . . . . . 13
THROTTLE VALVE CABLE . . . . . . . . . . . . . . . . . 9
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . 28
CONVERTER DRAINBACK CHECK VALVE
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FLUID AND FILTER REPLACEMENT . . . . . . . . 25
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . 25
FLUSHING COOLERS AND TUBES . . . . . . . . . 27
OIL COOLER FLOW CHECK . . . . . . . . . . . . . . 26
TRANSMISSION FILL PROCEDURE . . . . . . . . 26
REMOVAL AND INSTALLATION
BRAKE TRANSMISSION SHIFT INTERLOCK . . 32
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 32
GOVERNOR SOLENOID AND PRESSURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OUTPUT SHAFT FRONT BEARING . . . . . . . . . 38
OUTPUT SHAFT REAR BEARING . . . . . . . . . . 38
OVERDRIVE HOUSING BUSHING . . . . . . . . . . 38
OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . 36
PARK/NEUTRAL POSITION SWITCH . . . . . . . . 31
SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . 31
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . 29
TRANSMISSION COOLER LINE AND
FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 28
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 34
YOKE SEAL REPLACEMENT . . . . . . . . . . . . . . 30
DISASSEMBLY AND ASSEMBLY
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 71
FRONT SERVO PISTON . . . . . . . . . . . . . . . . . 67
OIL PUMP AND REACTION SHAFT SUPPORT . 68
OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . 81
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER . . . . . . . . . . . . . . . . . . . . 65
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 77
ZG TRANSMISSION AND TRANSFER CASE 21 - 1
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR SERVO PISTON . . . . . . . . . . . . . . . . . . 68
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 54
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CLEANING AND INSPECTION
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . 99
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . 100
FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . . . 99
OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . . . 101
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM/OVERDRIVE PISTON RETAINER . . . . 99
PLANETARY GEARTRAIN . . . . . . . . . . . . . . . 101
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 100
REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . . 100
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 99
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 96
ADJUSTMENTS
BAND ADJUSTMENTS . . . . . . . . . . . . . . . . . . 104
BRAKE TRANSMISSION SHIFT INTERLOCK . 102
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . 103
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 103
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 105
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . 105
SPECIFICATIONS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 117
SPECIAL TOOLS
RE TRANSMISSIONS . . . . . . . . . . . . . . . . . . . 119
GENERAL INFORMATION
42/44 RE TRANSMISSION
The 42/44RE i s a four speed ful l y automati c trans-
mi ssi on (Fi g. 1) wi th an el ectroni c governor. Fi rst
through thi rd gear ranges are provi ded by the
cl utches, bands, overrunni ng cl utch, and pl anetary
gear sets i n the transmi ssi on. Fourth gear range i s
provi ded by the overdri ve uni t that contai ns an over-
dri ve cl utch, di rect cl utch, pl anetary gear set, and
overrunni ng cl utch. The overdri ve cl utch i s appl i ed i n
fourth gear onl y. The di rect cl utch i s appl i ed i n al l
ranges except fourth gear. The torque converter
cl utch i s control l ed by the Powertrai n Control Mod-
ul e (PCM). The torque converter cl utch i s hydraul i -
cal l y appl i ed and i s rel eased when fl ui d i s vented
from the hydraul i c ci rcui t by the torque converter
control (TCC) sol enoi d on the val ve body. The torque
converter cl utch engages i n fourth gear, and i n thi rd
gear when the O/D swi tch i s OFF. Engagement
occurs when the vehi cl e i s movi ng at a steady speed
after the vehi cl e has warmed up. The torque con-
verter cl utch di sengages when the accel erator i s
appl i ed. The 42/44 RE transmi ssi on i s cool ed by an
i ntegral fl ui d cool er i nsi de the radi ator.
21 - 2 TRANSMISSION AND TRANSFER CASE ZG
F
i
g
.
1
4
2
/
4
4
R
E
T
r
a
n
s
m
i
s
s
i
o
n
ZG TRANSMISSION AND TRANSFER CASE 21 - 3
GENERAL INFORMATION (Continued)
TRANSMISSION IDENTIFICATION
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan gas-
ket surface (Fi g. 2). Refer to thi s i nformati on when
orderi ng repl acement parts.
RECOMMENDED FLUID
Mopar ATF Pl us, Type 7176 automati c transmi s-
si on fl ui d i s the recommended fl ui d for Chrysl er
automati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
ELECTRONIC LOCK-UP TORQUE CONVERTER
The torque converter i s a hydraul i c devi ce that
coupl es the engi ne crankshaft to the transmi ssi on.
The torque converter consi sts of an outer shel l wi th
an i nternal turbi ne, a stator, an overrunni ng cl utch,
an i mpel l er, and an el ectroni cal l y appl i ed converter
cl utch. Torque mul ti pl i cati on i s created when the sta-
tor di rects the hydraul i c fl ow from the turbi ne to
rotate the i mpel l er i n the di recti on the engi ne crank-
shaft i s turni ng. The turbi ne transfers power to the
pl anetary gear sets i n the transmi ssi on. The transfer
of power i nto the i mpel l er assi sts torque mul ti pl i ca-
ti on. At l ow vehi cl e-speed, the overrunni ng cl utch
hol ds the stator stati onary (duri ng torque mul ti pl i ca-
ti on) and al l ows the stator to freewheel at hi gh vehi -
cl e speed. The converter cl utch engagement reduces
engi ne speed. Cl utch engagement al so provi des
reduced transmi ssi on fl ui d temperatures. The torque
converter hub dri ves the transmi ssi on oi l (fl ui d)
pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure results in large amounts of
metal or fiber contamination in the fluid.
TRANSMISSION GEAR RATIOS
Gear rati os are:
1st 2.74:1
2nd 1.54:1
3rd 1.00:1
4th 0.69:1
Rev. 2.21
GEARSHIFT MECHANISM
The shi ft mechani sm i s cabl e operated and pro-
vi des si x shi ft posi ti ons. The shi ft posi ti ons are:
Park (P)
Reverse (R)
Neutral (N)
Dri ve (D)
Manual Second (2)
Manual Low (1)
Manual l ow (1) range provi des fi rst gear onl y.
Overrun braki ng i s al so provi ded i n thi s range. Man-
ual second (2) range provi des fi rst and second gear
onl y. Dri ve range provi des fi rst, second, thi rd, and
overdri ve fourth gear ranges. The shi ft i nto overdri ve
fourth gear range occurs onl y after the transmi ssi on
has compl eted the shi ft i nto (D) thi rd gear range. No
further movement of the shi ft mechani sm i s requi red
to compl ete the 3-4 shi ft.
DESCRIPTION AND OPERATION
ELECTRONIC GOVERNOR
Governor pressure i s control l ed el ectroni cal l y. Com-
ponents used for governor pressure control i ncl ude:
Governor body
Val ve body transfer pl ate
Governor pressure sol enoi d val ve
Governor pressure sensor
Fl ui d temperature thermi stor
Throttl e posi ti on sensor (TPS)
Transmi ssi on speed sensor
Powertrai n control modul e (PCM)
GOVERNOR PRESSURE SOLENOID VALVE
The sol enoi d val ve i s a duty-cycl e sol enoi d whi ch
regul ates the governor pressure needed for upshi fts
and downshi fts. I t i s an el ectro-hydraul i c devi ce
l ocated i n the governor body on the val ve body trans-
fer pl ate (Fi g. 3).
The i nl et si de of the sol enoi d val ve i s exposed to
normal transmi ssi on l i ne pressure. The outl et si de of
the val ve l eads to the val ve body governor ci rcui t.
Fig. 2 Transmission Part And Serial
NumberLocation
PART NUMBER BUILD DATE SERIAL NUM- BER
21 - 4 TRANSMISSION AND TRANSFER CASE ZG
GENERAL INFORMATION (Continued)
The sol enoi d val ve regul ates l i ne pressure to pro-
duce governor pressure. The average current sup-
pl i ed to the sol enoi d control s governor pressure. One
amp current produces zero kPa/psi governor pres-
sure. Zero amps sets the maxi mum governor pres-
sure.
The powertrai n control modul e (PCM) turns on the
trans control rel ay whi ch suppl i es el ectri cal power to
the sol enoi d val ve. Operati ng vol tage i s 12 vol ts
(DC). The PCM control s the ground si de of the sol e-
noi d usi ng the governor pressure sol enoi d control ci r-
cui t.
GOVERNOR PRESSURE SENSOR
The governor pressure sensor measures output
pressure of the governor pressure sol enoi d val ve (Fi g.
4).
The sensor output si gnal provi des the necessary
feedback to the PCM. Thi s feedback i s needed to ade-
quatel y control governor pressure.
GOVERNOR BODY AND TRANSFER PLATE
The transfer pl ate i s desi gned to suppl y transmi s-
si on l i ne pressure to the governor pressure sol enoi d
val ve and to return governor pressure.
The governor pressure sol enoi d val ve i s mounted i n
the governor body. The body i s bol ted to the l ower
si de of the transfer pl ate (Fi g. 4). The transfer pl ate
channel s l i ne pressure to the sol enoi d val ve through
the governor body. I t al so channel s governor pressure
from the sol enoi d val ve to the governor ci rcui t. I t i s
the sol enoi d val ve that devel ops the necessary gover-
nor pressure.
TRANSMISSION FLUID TEMPERATURE
THERMISTOR
Transmi ssi on fl ui d temperature readi ngs are sup-
pl i ed to the transmi ssi on control modul e by the ther-
mi stor. The temperature readi ngs are used to control
engagement of the fourth gear overdri ve cl utch, the
converter cl utch, and governor pressure. Normal
resi stance val ue for the thermi stor at room tempera-
ture i s approxi matel y 1000 ohms.
The PCM prevents engagement of the converter
cl utch and overdri ve cl utch, when fl ui d temperature
i s bel ow approxi matel y 10C (50F).
I f fl ui d temperature exceeds 126C (260F), the
PCM causes a 4-3 downshi ft and engage the con-
verter cl utch. Engagement i s accordi ng to the thi rd
gear converter cl utch engagement schedul e.
The overdri ve OFF l amp i n the i nstrument panel
i l l umi nates when the shi ft back to thi rd occurs. The
transmi ssi on wi l l not al l ow fourth gear operati on
unti l fl ui d temperature decreases to approxi matel y
110C (230F).
The thermi stor i s part of the governor pressure
sensor assembl y and i s i mmersed i n transmi ssi on
fl ui d at al l ti mes.
TRANSMISSION SPEED SENSOR
The speed sensor (Fi g. 5) i s l ocated i n the over-
dri ve gear case. The sensor i s posi ti oned over the
park gear and moni tors transmi ssi on output shaft
rotati ng speed. Speed sensor si gnal s are tri ggered by
the park gear l ugs as they rotate past the sensor
pi ckup face. I nput si gnal s from the sensor are sent to
the transmi ssi on control modul e for processi ng. The
vehi cl e speed sensor al so serves as a backup for the
transmi ssi on speed sensor. Si gnal s from thi s sensor
are shared wi th the powertrai n control modul e.
Fig. 3 Governor Pressure Solenoid Valve
SOLENOID FIL- TER GOVERNOR PRES- SURE SOLENOID
Fig. 4 Governor Pressure Sensor
RETAINING CLIP GOVERNOR BODY GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID TEMPERATURE THERMISTOR
Fig. 5 Transmission Output Speed Sensor
TRANSMISSION OUTPUT SHAFT SPEED SENSOR SEAL
ZG TRANSMISSION AND TRANSFER CASE 21 - 5
DESCRIPTION AND OPERATION (Continued)
THROTTLE POSITION SENSOR (TPS)
The TPS provi des throttl e posi ti on i nput si gnal s to
the PCM. Thi s i nput si gnal i s used to determi ne
overdri ve and converter cl utch shi ft schedul e and to
sel ect the proper governor curve.
POWERTRAIN CONTROL MODULE (PCM)
The PCM control s operati on of the converter
cl utch, overdri ve cl utch, and governor pressure sol e-
noi d.
The control modul e determi nes transmi ssi on shi ft
poi nts based on i nput si gnal s from the transmi ssi on
thermi stor, transmi ssi on output shaft speed sensor,
crankshaft posi ti on sensor, vehi cl e speed sensor,
throttl e posi ti on sensor, and battery temperature sen-
sor.
GOVERNOR PRESSURE CURVES
There are four governor pressure curves pro-
grammed i nto the transmi ssi on control modul e. The
di fferent curves al l ow the control modul e to adjust
governor pressure for varyi ng condi ti ons. One curve
i s used for operati on when fl ui d temperature i s at, or
bel ow, 1C (30F). A second curve i s used when fl ui d
temperature i s at, or above, 10C (50F) duri ng nor-
mal ci ty or hi ghway dri vi ng. A thi rd curve i s used
duri ng wi de-open throttl e operati on. The fourth curve
i s used when dri vi ng wi th the transfer case i n l ow
range.
SHIFT VALVE OPERATION
The shi ft val ves are moved by a combi nati on of
throttl e and governor pressure. The governor pres-
sure i s generated by el ectri cal components.
The condi ti ons under whi ch a shi ft to fourth wi l l
not occur are:
Overdri ve swi tch i s Off
Transmi ssi on fl ui d temperature i s bel ow 10 C
(50 F) or above 121 C (250 F)
Shi ft to thi rd not yet compl eted
Vehi cl e speed too l ow for 3-4 shi ft to occur
Battery temperature bel ow 5 F.
HYDRAULIC CONTROL SYSTEM
The hydraul i c control system provi des ful l y auto-
mati c operati on. The system performs fi ve basi c func-
ti ons whi ch are: pressure suppl y, pressure regul ati on,
fl ow control , cl utch/band appl i cati on, and l ubri cati on.
PRESSURE REGULATION
The pressure regul ator val ve mai ntai ns l i ne pres-
sure. The amount of pressure devel oped i s control l ed
by throttl e pressure whi ch i s dependent on the
degree of throttl e openi ng. The regul ator val ve i s
l ocated i n the val ve body.
The throttl e val ve determi nes l i ne pressure and
shi ft speed. Governor pressure i ncreases i n propor-
ti on to vehi cl e speed. The throttl e val ve control s
upshi ft and downshi ft speeds by regul ati ng pressure
accordi ng to throttl e posi ti on.
Shift Valve Flow Control
The manual val ve i s operated by the gearshi ft l i nk-
age and provi des the operati ng range sel ected by the
dri ver.
The 1-2 shi ft val ve provi des 1-2 or 2-1 shi fts and
the 2-3 shi ft val ve provi des 2-3 or 3-2 shi fts.
The ki ckdown val ve provi des forced 3-2 or 3-1
downshi fts dependi ng on vehi cl e speed. Downshi fts
occur when the throttl e i s opened beyond downshi ft
detent posi ti on. Detent i s reached just before wi de
open throttl e posi ti on.
The 2-3 val ve throttl e pressure pl ug provi des 3-2
downshi fts at varyi ng throttl e openi ngs dependi ng on
vehi cl e speed.
The 1-2 shi ft control val ve transmi ts 1-2 shi ft pres-
sure to the accumul ator pi ston. Thi s control s ki ck-
down band capaci ty on 1-2 upshi fts and 3-2
downshi fts.
The 3-4 shi ft, qui ck fi l l , and ti mi ng val ves pl us the
3-4 accumul ator, are onl y actuated when the over-
dri ve sol enoi d i s energi zed. The sol enoi d contai ns a
check bal l that control s a vent port to the 3-4 val ves.
The check bal l ei ther di verts l i ne pressure away from
or di rectl y to the 3-4 val ves.
The l i mi t val ve determi nes maxi mum speed at
whi ch a 3-2 part throttl e ki ckdown can be made. On
transmi ssi ons wi thout a l i mi t val ve, maxi mum speed
for a 3-2 ki ckdown i s at detent posi ti on.
The 2-3 shuttl e val ve has two functi ons. The fi rst
i s fast front band rel ease and smooth engagement
duri ng l i ft-foot 2-3 upshi fts. The second i s to regul ate
front cl utch and band appl i cati on duri ng 3-2 down-
shi fts.
The 3-4 ti mi ng val ve i s moved by l i ne pressure
comi ng through the 3-4 shi ft val ve. The ti mi ng val ve
hol ds the 2-3 shi ft val ve i n an upshi ft posi ti on. The
purpose i s to prevent the 2-3 val ve from up or down-
shi fti ng before the 3-4 val ve.
The 3-4 accumul ator i s mounted on the overdri ve
housi ng and performs the same functi on as the 2-3
accumul ator; i t i s used to smooth engagement duri ng
a 3-4 shi ft.
The 3-4 qui ck fi l l val ve provi des faster engagement
of the overdri ve cl utch duri ng 3-4 upshi fts. The val ve
temporari l y bypasses the cl utch pi ston feed ori fi ce at
the start of a 3-4 upshi ft. Thi s exposes a l arger pas-
sage i nto the pi ston retai ner resul ti ng i n a much
faster cl utch fi l l and appl y sequence. The qui ck fi l l
val ve does not bypass the regul ar cl utch feed ori fi ce
throughout the 3-4 upshi ft. I nstead, once a predeter-
mi ned pressure devel ops wi thi n the cl utch, the val ve
cl oses the bypass. Cl utch fi l l i s then compl eted
through the regul ar feed ori fi ce.
21 - 6 TRANSMISSION AND TRANSFER CASE ZG
DESCRIPTION AND OPERATION (Continued)
The swi tch val ve di rects fl ui d appl y pressure to the
converter cl utch i n one posi ti on and rel eases i t i n the
opposi te posi ti on. I t al so di rects oi l to the cool i ng and
l ube ci rcui ts. The swi tch val ve regul ates oi l pressure
to the torque converter by l i mi ti ng maxi mum oi l
pressure to 130 psi .
OVERDRIVE OFF SWITCH
The overdri ve OFF (control ) swi tch i s l ocated i n
the i nstrument panel . The swi tch i s a momentary
contact devi ce that si gnal s the PCM to toggl e current
status of the overdri ve functi on. At key-on, overdri ve
operati on i s al l owed. Pressi ng the swi tch once causes
the overdri ve OFF mode to be entered and the over-
dri ve OFF swi tch l amp to be i l l umi nated. Pressi ng
the swi tch a second ti me causes normal overdri ve
operati on to be restored and the overdri ve l amp to be
turned off. The overdri ve OFF mode defaul ts to ON
after the i gni ti on swi tch i s cycl ed OFF and ON. The
normal posi ti on for the control swi tch i s the ON posi -
ti on. The swi tch must be i n thi s posi ti on to energi ze
the sol enoi d and al l ow a 3-4 upshi ft. The control
swi tch i ndi cator l i ght i l l umi nates onl y when the over-
dri ve swi tch i s turned to the OFF posi ti on, or when
i l l umi nated by the transmi ssi on control modul e.
3-4 SHIFT SEQUENCE
The overdri ve cl utch i s appl i ed i n fourth gear onl y.
The di rect cl utch i s appl i ed i n al l ranges except
fourth gear. Fourth gear overdri ve range i s el ectron-
i cal l y control l ed and hydraul i cal l y acti vated. Vari ous
sensor i nputs are suppl i ed to the powertrai n control
modul e to operate the overdri ve sol enoi d on the val ve
body. The sol enoi d contai ns a check bal l that opens
and cl oses a vent port i n the 3-4 shi ft val ve feed pas-
sage. The overdri ve sol enoi d (and check bal l ) are not
energi zed i n fi rst, second, thi rd, or reverse gear. The
vent port remai ns open, di verti ng l i ne pressure from
the 2-3 shi ft val ve away from the 3-4 shi ft val ve. The
overdri ve control swi tch must be i n the ON posi ti on
to transmi t overdri ve status to the PCM. A 3-4
upshi ft occurs onl y when the overdri ve sol enoi d i s
energi zed by the PCM. The PCM energi zes the over-
dri ve sol enoi d duri ng the 3-4 upshi ft. Thi s causes the
sol enoi d check bal l to cl ose the vent port al l owi ng
l i ne pressure from the 2-3 shi ft val ve to act di rectl y
on the 3-4 upshi ft val ve. Li ne pressure on the 3-4
shi ft val ve overcomes val ve spri ng pressure movi ng
the val ve to the upshi ft posi ti on. Thi s acti on exposes
the feed passages to the 3-4 ti mi ng val ve, 3-4 qui ck
fi l l val ve, 3-4 accumul ator, and ul ti matel y to the
overdri ve pi ston. Li ne pressure through the ti mi ng
val ve moves the overdri ve pi ston i nto contact wi th
the overdri ve cl utch. The di rect cl utch i s di sengaged
before the overdri ve cl utch i s engaged. The boost
val ve provi des i ncreased fl ui d appl y pressure to the
overdri ve cl utch duri ng 3-4 upshi fts, and when accel -
erati ng i n fourth gear. The 3-4 accumul ator cushi ons
overdri ve cl utch engagement to smooth 3-4 upshi fts.
The accumul ator i s charged at the same ti me as
appl y pressure acts agai nst the overdri ve pi ston.
CONVERTER CLUTCH ENGAGEMENT
Converter cl utch engagement i n thi rd or fourth
gear range i s control l ed by sensor i nputs to the pow-
ertrai n control modul e. I nputs that determi ne cl utch
engagement are: cool ant temperature, engi ne rpm,
vehi cl e speed, throttl e posi ti on, and mani fol d vac-
uum. The torque converter cl utch i s engaged by the
cl utch sol enoi d on the val ve body. The cl utch can be
engaged i n thi rd and fourth gear ranges dependi ng
on overdri ve control swi tch posi ti on. I f the overdri ve
control swi tch i s i n the normal ON posi ti on, the
cl utch wi l l engage after the shi ft to fourth gear, and
above approxi matel y 72 km/h (45 mph). I f the control
swi tch i s i n the OFF posi ti on, the cl utch wi l l engage
after the shi ft to thi rd gear, at approxi matel y 56
km/h (35 mph) at l i ght throttl e.
CONVERTER DRAINBACK VALVE
The drai nback val ve i s l ocated i n the transmi ssi on
cool er outl et (pressure) l i ne. The val ve prevents fl ui d
from drai ni ng from the converter i nto the cool er and
l i nes when the vehi cl e i s shut down for l engthy peri -
ods. Producti on val ves have a hose ni ppl e at one end,
whi l e the opposi te end i s threaded for a fl are fi tti ng.
Al l val ves have an arrow (or si mi l ar mark) to i ndi -
cate di recti on of fl ow through the val ve.
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 6). The system l ocks the shi fter i nto the
PARK posi ti on. The I nterl ock system i s engaged
whenever the i gni ti on swi tch i s i n the LOCK or
ACCESSORY posi ti on. An addi ti onal el ectri cal l y acti -
vated feature wi l l prevent shi fti ng out of the PARK
posi ti on unl ess the brake pedal i s depressed at l east
one-hal f an i nch. A magneti c hol di ng devi ce i n l i ne
wi th the park l ock cabl e i s enegi zed i n PARK when
the i gni ti on i s i n the OFF-LOCK posi ti on.When the
key i s i n the OFF or RUN posi ti on and the brake
pedal i s depressed, the shi fter i s unl ocked and wi l l
move i nto any posi ti on. The i nterl ock system al so
prevents the i gni ti on swi tch from bei ng turned to the
LOCK or ACCESSORY posi ti on (Fi g. 7). Unl ess the
shi fter i s ful l y l ocked i nto the PARK posi ti on.
ZG TRANSMISSION AND TRANSFER CASE 21 - 7
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
AUTOMATIC TRANSMISSION DIAGNOSIS
Automati c transmi ssi on probl ems can be a resul t of
poor engi ne performance, i ncorrect fl ui d l evel , i ncor-
rect l i nkage or cabl e adjustment, band or hydraul i c
control pressure adjustments, hydraul i c system mal -
functi ons or el ectri cal /mechani cal component mal -
functi ons. Begi n di agnosi s by checki ng the easi l y
accessi bl e i tems such as: fl ui d l evel and condi ti on,
l i nkage adjustments and el ectri cal connecti ons. A
road test wi l l determi ne i f further di agnosi s i s neces-
sary.
PRELIMINARY DIAGNOSIS
Two basi c procedures are requi red. One procedure
for vehi cl es that are dri vabl e and an al ternate proce-
dure for di sabl ed vehi cl es (wi l l not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(2) Check fl ui d l evel and condi ti on.
(3) Adjust throttl e and gearshi ft l i nkage i f com-
pl ai nt was based on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform stal l test i f compl ai nt i s based on sl ug-
gi sh accel erati on. Or, i f abnormal throttl e openi ng i s
needed to mai ntai n normal speeds wi th a properl y
tuned engi ne.
(6) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(7) Perform ai r-pressure test to check cl utch-band
operati on.
VEHICLE IS DISABLED
(1) Check fl ui d l evel and condi ti on.
(2) Check for broken or di sconnected gearshi ft or
throttl e l i nkage.
Fig. 6 Ignition Interlock Cable Routing
STEERING COLUMN ASSEM- BLY SCREW DASH PANEL CLIP CABLE UNDER RIGHT STUD CLIP ON TUN- NEL INSULA- TION ADJUSTMENT SHIFTER ALIGNING PIN INTERLOCK CABLE
ACCELERATOR PEDAL
Fig. 7 Ignition Key Cylinder Actuation
ACC LOCK OFF RUN START
SLIDER LOCKED CAM RETURN SPRING INTERLOCK CABLE CAM
SLIDER
21 - 8 TRANSMISSION AND TRANSFER CASE ZG
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri ve pl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
PARK/NEUTRAL POSITION SWITCH
The center termi nal of the park/neutral posi ti on
swi tch i s the starter-ci rcui t termi nal . I t provi des the
ground for the starter sol enoi d ci rcui t through the
sel ector l ever i n PARK and NEUTRAL posi ti ons onl y.
The outer termi nal s on the swi tch are for the backup
l amp ci rcui t.
SWITCH TEST
To test the swi tch, remove the wi ri ng connector.
Test for conti nui ty between the center termi nal and
the transmi ssi on case. Conti nui ty shoul d exi st onl y
when the transmi ssi on i s i n PARK or NEUTRAL.
Shi ft the transmi ssi on i nto REVERSE and test
conti nui ty at the swi tch outer termi nal s. Conti nui ty
shoul d exi st onl y when the transmi ssi on i s i n
REVERSE. Conti nui ty shoul d not exi st between the
outer termi nal s and the case.
Check gearshi ft l i nkage adjustment before repl ac-
i ng a swi tch that tests faul ty.
OVERDRIVE ELECTRICAL CONTROLS
The overdri ve off swi tch, val ve body sol enoi d, case
connectors and rel ated wi ri ng can al l be tested wi th
a 12 vol t test l amp or a vol t/ohmmeter. Check conti -
nui ty of each component when di agnosi s i ndi cates
thi s i s necessary. Refer to Group 8W, Wi ri ng Di a-
grams, for component l ocati ons and ci rcui t i nforma-
ti on.
Swi tch and sol enoi d conti nui ty shoul d be checked
whenever the transmi ssi on fai l s to shi ft i nto fourth
gear range.
BRAKE TRANSMISSION SHIFT INTERLOCK
(1) Veri fy that the key can onl y be removed i n the
PARK posi ti on
(2) When the shi ft l ever i s i n PARK And the shi ft
handl e pushbutton i s i n the OUT posi ti on, the i gni -
ti on key cyl i nder shoul d rotate freel y from OFF to
LOCK. When the shi fter i s i n any other gear or neu-
tral posi ti on, the i gni ti on key cyl i nder shoul d not
rotate to the LOCK posi ti on.
(3) Shi fti ng out of PARK shoul d be possi bl e when
the i gni ti on key cyl i nder i s i n the OFF posi ti on.
(4) Shi fti ng out of PARK shoul d not be possi bl e
whi l e appl yi ng 25 l b. maxi mum handl e pushbutton
force and i gni ti on key cyl i nder i s i n the RUN or
START posi ti ons unl ess the foot brake pedal i s
depressed approxi matel y 1/2 i nch (12mm).
(5) Shi fti ng out of PARK shoul d not be possi bl e
when the i gni ti on key cyl i nder i s i n the ACCESSORY
or LOCK posi ti ons.
(6) Shi fti ng between any gears, NEUTRAL or i nto
PARK may be done wi thout depressi ng foot brake
pedal wi th i gni ti on swi tch i n RUN or START posi -
ti ons and vehi cl e stati onary or i n moti on.
GEARSHIFT CABLE
(1) The fl oor shi fter l ever and gate posi ti ons
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
l ever i n PARK or NEUTRAL gate posi ti ons onl y.
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti onAppl y forward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(b) PARK posi ti onAppl y rearward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(c) NEUTRAL posi ti onNormal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti onEngi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from neutral to reverse.
THROTTLE VALVE CABLE
Transmi ssi on throttl e val ve cabl e adjustment i s
extremel y i mportant to proper operati on. Thi s adjust-
ment posi ti ons the throttl e val ve, whi ch control s shi ft
speed, qual i ty, and part-throttl e downshi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve. Refer to the Adjust-
ments secti on for adjustment procedure.
Shi ft-cabl e adjustment i s i mportant because i t
posi ti ons the val ve body manual val ve. I ncorrect
adjustment wi l l cause creepi ng i n NEUTRAL, prema-
ture cl utch wear, del ayed engagement i n any gear, or
the engi ne wi l l not crank i n PARK or NEUTRAL
posi ti on.
ZG TRANSMISSION AND TRANSFER CASE 21 - 9
DIAGNOSIS AND TESTING (Continued)
Proper operati on of the park/neutral posi ti on
swi tch wi l l provi de a qui ck check of shi ft cabl e
adjustment.
ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that di agnosti c troubl e
codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, band or overrunni ng cl utch probl ems. I f the
condi ti on i s advanced, an overhaul wi l l be necessary
to restore normal operati on.
A sl i ppi ng cl utch or band can often be determi ned
by compari ng whi ch i nternal uni ts are appl i ed i n the
vari ous gear ranges. The Cl utch and Band Appl i ca-
ti on chart provi des a basi s for anal yzi ng road test
resul ts.
ANALYZING ROAD TEST
Refer to the Cl utch and Band Appl i cati on chart
and note whi ch el ements are i n use i n the vari ous
gear ranges.
Note that the rear cl utch i s appl i ed i n al l forward
ranges (D, 2, 1). The transmi ssi on overrunni ng cl utch
i s appl i ed i n fi rst gear (D, 2 and 1 ranges) onl y. The
rear band i s appl i ed i n 1 and R range onl y.
Note that the overdri ve cl utch i s appl i ed onl y i n
fourth gear and the overdri ve di rect cl utch and over-
runni ng cl utch are appl i ed i n al l ranges except fourth
gear.
For exampl e: I f sl i ppage occurs i n fi rst gear i n D
and 2 range but not i n 1 range, the transmi ssi on
overrunni ng cl utch i s faul ty. Si mi l arl y, i f sl i ppage
occurs i n any two forward gears, the rear cl utch i s
sl i ppi ng.
Appl yi ng the same method of anal ysi s, note that
the front and rear cl utches are appl i ed si mul ta-
neousl y onl y i n D range thi rd and fourth gear. I f the
transmi ssi on sl i ps i n thi rd gear, ei ther the front
cl utch or the rear cl utch i s sl i ppi ng.
I f the transmi ssi on sl i ps i n fourth gear but not i n
thi rd gear, the overdri ve cl utch i s sl i ppi ng. By sel ect-
i ng another gear whi ch does not use these cl utches,
the sl i ppi ng uni t can be determi ned. For exampl e, i f
the transmi ssi on al so sl i ps i n Reverse, the front
cl utch i s sl i ppi ng. I f the transmi ssi on does not sl i p i n
Reverse, the rear cl utch i s sl i ppi ng.
I f sl i ppage occurs duri ng the 3-4 shi ft or onl y i n
fourth gear, the overdri ve cl utch i s sl i ppi ng. Si mi -
l arl y, i f the di rect cl utch were to fai l , the transmi s-
si on woul d l ose both reverse gear and overrun
braki ng i n 2 posi ti on (manual second gear).
I f the transmi ssi on wi l l not shi ft to fourth gear, the
control swi tch, overdri ve sol enoi d or rel ated wi ri ng
may al so be the probl em cause.
Thi s process of el i mi nati on can be used to i denti fy
a sl i ppi ng uni t and check operati on. Proper use of
the Cl utch and Band Appl i cati on Chart i s the key.
Al though road test anal ysi s wi l l hel p determi ne the
sl i ppi ng uni t, the actual cause of a mal functi on usu-
al l y cannot be determi ned unti l hydraul i c and ai r
SHIFT LEVER
POSITION
TRANSMISSION CLUTCHES AND BANDS OVERDRIVE CLUTCHES
FRONT
CLUTCH
FRONT
BAND
REAR
CLUTCH
REAR
BAND
OVERRUN
CLUTCH
OVER-
DRIVE
CLUTCH
DIRECT
CLUTCH
OVERRUN
CLUTCH
Reverse X X
Drive Range
First X X X X
Second X X X X
Third X X X X
Fourth X X X
2-Range
(Manual
Second)
X X X X X
1-Range
(Manual Low)
X X X X X
Clutch And Band Application Chart
21 - 10 TRANSMISSION AND TRANSFER CASE ZG
DIAGNOSIS AND TESTING (Continued)
pressure tests are performed. Practi cal l y any condi -
ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Unl ess a mal functi on i s obvi ous, such as no dri ve
i n D range fi rst gear, do not di sassembl e the trans-
mi ssi on. Perform the hydraul i c and ai r pressure tests
to hel p determi ne the probabl e cause.
HYDRAULIC PRESSURE TEST
Hydraul i c test pressures range from a l ow of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port i n reverse.
An accurate tachometer and pressure test gauges
are requi red. Test Gauge C-3292 has a 100 psi range
and i s used at the accumul ator, governor, and front
servo ports. Test Gauge C-3293-SP has a 300 psi
range and i s used at the rear servo and overdri ve
ports where pressures exceed 100 psi .
Pressure Test Port Loc ations
Test ports are l ocated at both si des of the transmi s-
si on case (Fi g. 8).
Li ne pressure i s checked at the accumul ator port
on the ri ght si de of the case. The front servo pressure
port i s at the ri ght si de of the case just behi nd the
fi l l er tube openi ng.
The rear servo and governor pressure ports are at
the ri ght rear of the transmi ssi on case. The overdri ve
cl utch pressure port i s at the l eft rear of the case.
Test One - Transmission In Manual Low
NOTE: This test checks pump output, pressure reg-
ulation, and condition of the rear clutch and servo
circuit. Both test gauges are required for this test.
(1) Connect tachometer to engi ne. Posi ti on tachom-
eter so i t can be observed from dri ver seat i f hel per
wi l l be operati ng engi ne. Rai se vehi cl e on hoi st that
wi l l al l ow rear wheel s to rotate freel y.
(2) Connect 100 psi Gauge C-3292 to accumul ator
port. Then connect 300 psi Gauge C-3293-SP to rear
servo port.
(3) Di sconnect throttl e and gearshi ft cabl es from
l evers on transmi ssi on val ve body manual shaft.
(4) Have hel per start and run engi ne at 1000 rpm.
(5) Move transmi ssi on shi ft l ever ful l y forward
i nto 1 range.
(6) Gradual l y move transmi ssi on throttl e l ever
from ful l forward to ful l rearward posi ti on and note
pressures on both gauges:
Li ne pressure at accumul ator port shoul d be
54-60 psi (372-414 kPa) wi th throttl e l ever forward
and gradual l y i ncrease to 90-96 psi (621-662 kPa) as
throttl e l ever i s moved rearward.
Rear servo pressure shoul d be same as l i ne pres-
sure wi thi n 3 psi (20.68 kPa).
Test Two Transmission In 2 Range
NOTE: This test checks pump output, line pressure
and pressure regulation. Use 100 psi Test Gauge
C-3292 for this test.
(1) Leave vehi cl e i n pl ace on hoi st and l eave Test
Gauge C-3292 connected to accumul ator port.
(2) Have hel per start and run engi ne at 1000 rpm.
(3) Move transmi ssi on shi ft l ever one detent rear-
ward from ful l forward posi ti on. Thi s i s 2 range.
(4) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and read pressure on
gauge.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease to 90-96 psi (621-662 kPa) as l ever i s moved
rearward.
Test Three Transmission In D Range Third Gear
NOTE: This test checks pressure regulation and
condition of the clutch circuits. Both test gauges
are required for this test.
(1) Turn OD swi tch off.
(2) Leave vehi cl e on hoi st and l eave Gauge C-3292
i n pl ace at accumul ator port.
Fig. 8 Pressure Test Port Locations
OVERDRIVE CLUTCH TEST PORT
GOVERNOR TEST PORT
ZG TRANSMISSION AND TRANSFER CASE 21 - 11
DIAGNOSIS AND TESTING (Continued)
(3) Move Gauge C-3293-SP over to front servo port
for thi s test.
(4) Have hel per start and run engi ne at 1600 rpm
for thi s test.
(5) Move transmi ssi on shi ft l ever two detents rear-
ward from ful l forward posi ti on. Thi s i s D range.
(6) Read pressures on both gauges as transmi ssi on
throttl e l ever i s gradual l y moved from ful l forward to
ful l rearward posi ti on:
Li ne pressure at accumul ator i n D range thi rd
gear, shoul d be 54-60 psi (372-414 kPa) wi th throttl e
l ever forward and i ncrease as l ever i s moved rear-
ward.
Front servo pressure i n D range thi rd gear,
shoul d be wi thi n 3 psi (21 kPa) of l i ne pressure up to
ki ckdown poi nt.
Test Four Transmission In Reverse
NOTE: This test checks pump output, pressure reg-
ulation and the front clutch and rear servo circuits.
Use 300 psi Test Gauge C-3293-SP for this test.
(1) Leave vehi cl e on hoi st and l eave gauge C3292
i n pl ace at accumul ator port.
(2) Move 300 psi Gauge C-3293-SP back to rear
servo port.
(3) Have hel per start and run engi ne at 1600 rpm
for test.
(4) Move transmi ssi on shi ft l ever four detents
rearward from ful l forward posi ti on. Thi s i s Reverse
range.
(5) Move transmi ssi on throttl e l ever ful l y forward
then ful l y rearward and note readi ng at Gauge
C-3293-SP.
(6) Pressure shoul d be 145 - 175 psi (1000-1207
kPa) wi th throttl e l ever forward and i ncrease to 230 -
280 psi (1586-1931 kPa) as l ever i s gradual l y moved
rearward.
Test Five Governor Pressure
NOTE: This test checks governor operation by
measuring governor pressure response to changes
in vehicle speed. It is usually not necessary to
check governor operation unless shift speeds are
incorrect or if the transmission will not downshift.
The test should be performed on the road or on a
hoist that will allow the rear wheels to rotate freely.
(1) Move 100 psi Test Gauge C-3292 to governor
pressure port.
(2) Move transmi ssi on shi ft l ever two detents rear-
ward from ful l forward posi ti on. Thi s i s D range.
(3) Have hel per start and run engi ne at curb i dl e
speed. Then fi rml y appl y servi ce brakes so wheel s
wi l l not rotate.
(4) Note governor pressure:
Governor pressure shoul d be no more than 20.6
kPa (3 psi ) at curb i dl e speed and wheel s not rotat-
i ng.
I f pressure exceeds 20.6 kPa (3 psi ), a faul t
exi sts i n governor pressure control system.
(5) Rel ease brakes, sl owl y i ncrease engi ne speed,
and observe speedometer and pressure test gauge (do
not exceed 30 mph on speedometer). Governor pres-
sure shoul d i ncrease i n proporti on to vehi cl e speed.
Or approxi matel y 6.89 kPa (1 psi ) for every 1 mph.
(6) Governor pressure ri se shoul d be smooth and
drop back to no more than 20.6 kPa (3 psi ), after
engi ne returns to curb i dl e and brakes are appl i ed to
prevent wheel s from rotati ng.
(7) Compare resul ts of pressure test wi th anal ysi s
chart.
Test Six Transmission In Overdrive Fourth Gear
NOTE: This test checks line pressure at the over-
drive clutch in fourth gear range. Use 300 psi Test
Gauge C-3292 for this test. The test should be per-
formed on the road or on a chassis dyno.
(1) Remove tachometer; i t i s not needed for thi s
test.
(2) Move 300 psi Gauge to overdri ve cl utch pres-
sure test port. Then remove other gauge and rei nstal l
test port pl ug.
(3) Lower vehi cl e.
(4) Turn OD swi tch on.
(5) Secure test gauge so i t can be vi ewed from
dri vers seat.
(6) Start engi ne and shi ft i nto D range.
(7) I ncrease vehi cl e speed gradual l y unti l 3-4 shi ft
occurs and note gauge pressure.
(8) Pressure shoul d be 469-496 kPa (68-72 psi )
wi th cl osed throttl e and i ncrease to 620-827 kPa (90-
120 psi ) at 1/2 to 3/4 throttl e. Note that pressure can
i ncrease to around 896 kPa (130 psi ) at ful l throttl e.
(9) Return to shop or move vehi cl e off chassi s
dyno.
CONVERTER STALL TEST
Stal l testi ng i nvol ves determi ni ng maxi mum
engi ne speed obtai nabl e at ful l throttl e wi th the rear
wheel s l ocked and the transmi ssi on i n D range. Thi s
test checks the hol di ng abi l i ty of the converter over-
runni ng and transmi ssi on cl utches.
WARNING: NEVER ALLOW ANYONE TO STAND
DIRECTLY IN LINE WITH THE VEHICLE FRONT OR
REAR DURING A STALL TEST. ALWAYS BLOCK
THE WHEELS AND FULLY APPLY THE SERVICE
AND PARKING BRAKES DURING THE TEST.
21 - 12 TRANSMISSION AND TRANSFER CASE ZG
DIAGNOSIS AND TESTING (Continued)
STALL TEST PROCEDURE
(1) Connect tachometer to engi ne. Posi ti on tachom-
eter so i t can be vi ewed from dri vers seat.
(2) Dri ve vehi cl e to bri ng transmi ssi on fl ui d up to
normal operati ng temperature. Vehi cl e can be dri ven
on road or on chassi s dynamometer, i f avai l abl e.
(3) Check transmi ssi on fl ui d l evel . Add fl ui d i f nec-
essary.
(4) Bl ock front wheel s.
(5) Ful l y appl y servi ce and parki ng brakes.
(6) Open throttl e compl etel y and record maxi mum
engi ne speed regi stered on tachometer. I t takes 4-10
seconds to reach max rpm. Once max rpm has
been achieved, do not hold wide open throttle
for more than 4-5 seconds.
CAUTION: Stalling the converter causes a rapid
increase in fluid temperature. To avoid fluid over-
heating, hold the engine at maximum rpm for no
more than 5 seconds. If engine exceeds 2500 rpm
during the test, release the accelerator pedal imme-
diately; transmission clutch slippage is occurring.
(7) I f a second stal l test i s requi red, cool down
fl ui d before proceedi ng. Shi ft i nto NEUTRAL and run
engi ne at 1000 rpm for 20-30 seconds to cool fl ui d.
STALL TEST ANALYSIS
Stall Speed Too High
I f the stal l speed exceeds 2500 rpm, transmi ssi on
cl utch sl i ppage i s i ndi cated.
Stall Speed Low
Low stal l speed wi th a properl y tuned engi ne i ndi -
cate a torque converter overrunni ng cl utch probl em.
The condi ti on shoul d be confi rmed by road testi ng. A
stal l speed 250-350 rpm bel ow normal i ndi cates the
converter overrunni ng cl utch i s sl i ppi ng. The vehi cl e
al so exhi bi ts poor accel erati on but operates normal l y
once hi ghway crui se speeds are reached. Torque con-
verter repl acement wi l l be necessary.
Stall Speed Normal But Ac c eleration Poor
I f stal l speeds are normal (1800-2300 rpm) but
abnormal throttl e openi ng i s requi red for accel era-
ti on, or to mai ntai n crui se speed, the converter over-
runni ng cl utch i s sei zed. The torque converter wi l l
have to be repl aced.
Converter Noise During Test
A whi ni ng noi se caused by fl ui d fl ow i s normal dur-
i ng a stal l test. However, l oud metal l i c noi ses i ndi -
cate a damaged converter. To confi rm that the noi se
i s ori gi nati ng from the converter, operate the vehi cl e
at l i ght throttl e i n DRI VE and NEUTRAL on a hoi st
PRESSURE TEST ANALYSIS CHART
TEST CONDITION INDICATION
Line pressure OK during any one
test
Pump and regulator valve OK
Line pressure OK in R but low in
D, 2, 1
Leakage in rear clutch area (seal rings, clutch seals)
Pressure low in D Fourth Gear
Range
Overdrive clutch piston seal, or check ball problem
Pressure OK in 1, 2 but low in D3
and R
Leakage in front clutch area
Pressure OK in 2 but low in R and
1
Leakage in rear servo
Front servo pressure low in 2 Leakage in servo; broken servo ring or cracked servo piston
Pressure low in all positions Clogged filter, stuck regulator valve, worn or faulty pump, low oil level
Governor pressure too high at idle
speed
Governor pressure solenoid valve system fault. Refer to diagnostic book.
Governor pressure low at all mph
figures
Faulty governor pressure solenoid, transmission control module, or governor
pressure sensor
Lubrication pressure low at all
throttle positions
Clogged fluid cooler or lines, seal rings leaking, worn pump bushings, pump,
clutch retainer, or clogged filter.
Line pressure high Output shaft plugged, sticky regulator valve
Line pressure low Sticky regulator valve, clogged filter, worn pump
ZG TRANSMISSION AND TRANSFER CASE 21 - 13
DIAGNOSIS AND TESTING (Continued)
and l i sten for noi se comi ng from the converter hous-
i ng.
AIR TESTING TRANSMISSION CLUTCH AND BAND
OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on front/rear cl utch and band operati on. The test
can be conducted wi th the transmi ssi on ei ther i n the
vehi cl e or on the work bench, as a fi nal check, after
overhaul .
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
servo and cl utch appl y passages are shown (Fi g. 9).
Front Clutc h Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through front cl utch appl y pas-
sage. Pi ston movement can be fel t and a soft thump
heard as the cl utch appl i es.
Rear Clutc h Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through rear cl utch appl y passage.
Pi ston movement can be fel t and a soft thump heard
as the cl utch appl i es.
Front Servo Air Test
Appl y ai r pressure to the front servo appl y pas-
sage. The servo rod shoul d extend and cause the
band to ti ghten around the drum. Spri ng pressure
shoul d rel ease the servo when ai r pressure i s
removed.
Rear Servo Air Test
Appl y ai r pressure to the rear servo appl y passage.
The servo rod shoul d extend and cause the band to
ti ghten around the drum. Spri ng pressure shoul d
rel ease the servo when ai r pressure i s removed.
CONVERTER HOUSING FLUID LEAK DIAGNOSIS
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Pump seal l eaks tend to move al ong the
dri ve hub and onto the rear of the converter. Pump
O-ri ng or pump body l eaks fol l ow the same path as a
seal l eak (Fi g. 10). Pump vent or pump attachi ng bol t
l eaks are general l y deposi ted on the i nsi de of the
converter housi ng and not on the converter i tsel f
(Fi g. 10). Pump seal or gasket l eaks usual l y travel
down the i nsi de of the converter housi ng. Front band
l ever pi n pl ug l eaks are general l y deposi ted on the
housi ng and not on the converter.
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
(1) Leaks at the wel d joi nt around the outsi de
di ameter wel d (Fi g. 11).
(2) Leaks at the converter hub wel d (Fi g. 11).
CONVERTER HOUSING AREA LEAK
CORRECTION
(1) Remove converter.
(2) Ti ghten front band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
Fig. 9 Air Pressure Test Passages
REAR SERVO APPLY
FRONT SERVO APPLY
PUMP SUCTION
Fig. 10 Converter Housing Leak Paths
PUMP SEAL PUMP VENT PUMPBOLT PUMP GASKET CONVERTER HOUSING CONVERTER REAR MAIN SEAL LEAK
21 - 14 TRANSMISSION AND TRANSFER CASE ZG
DIAGNOSIS AND TESTING (Continued)
front/rear cl utches from comi ng out when oi l pump i s
removed.
(3) Remove oi l pump and remove pump seal .
I nspect pump housi ng drai nback and vent hol es for
obstructi ons. Cl ear hol es wi th sol vent and wi re.
(4) I nspect pump bushi ng and converter hub. I f
bushi ng i s scored, repl ace i t. I f converter hub i s
scored, ei ther pol i sh i t wi th crocus cl oth or repl ace
converter.
(5) I nstal l new pump seal , O-ri ng, and gasket.
Repl ace oi l pump i f cracked, porous or damaged i n
any way.
(6) Loosen ki ckdown l ever pi n access pl ug three
turns. Appl y Locti te 592, or Permatex No. 2 to pl ug
threads and ti ghten pl ug to 17 Nm (150 i n. l bs.)
torque.
(7) Adjust front band.
(8) Lubri cate pump seal and converter hub wi th
transmi ssi on fl ui d or petrol eum jel l y and i nstal l con-
verter.
(9) I nstal l transmi ssi on and converter housi ng
dust shi el d.
(10) Lower vehi cl e.
DIAGNOSIS TABLES AND CHARTS RE
TRANSMISSION
The di agnosi s charts provi de addi ti onal reference
when di agnosi ng a transmi ssi on faul t. The charts
provi de general i nformati on on a vari ety of transmi s-
si on, overdri ve uni t and converter cl utch faul t condi -
ti ons.
The hydraul i c fl ow charts i n the Schemati cs and
Di agrams secti on of thi s group, outl i ne fl ui d fl ow and
hydraul i c ci rcui try. Ci rcui t operati on i s provi ded for
neutral , thi rd, fourth and reverse gear ranges. Nor-
mal worki ng pressures are al so suppl i ed for each of
the gear ranges.
Fig. 11 Converter Leak PointsTypical
OUTSIDE DIAMETER WELD TORQUE CONVERTER HUB WELD STARTER RING GEAR LUG
ZG TRANSMISSION AND TRANSFER CASE 21 - 15
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
HARSH ENGAGEMENT (FROM
NEUTRAL TO DRIVE OR REVERSE)
1. Fluid Level Low 1. Add Fluid
2. Throttle Linkage Misadjusted 2. Adjust linkage - setting may be too
long.
3. Mount and Driveline Bolts Loose 3. Check engine mount, transmission
mount, propeller shaft, rear spring to
body bolts, rear control arms,
crossmember and axle bolt torque.
Tighten loose bolts and replace missing
bolts.
4. U-Joint Worn/Broken 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Misadjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check
ball installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component damaged.
10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch Faulty. 11. Replace converter and flush cooler
and line before installing new converter.
DELAYED ENGAGEMENT (FROM
NEUTRAL TO DRIVE OR REVERSE)
1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Misadjusted. 3. Adjust linkage and repair linkage if
worn or damaged.
4. Torque Converter Drain Back (Oil
drains from torque converter into
transmission sump)
4. If vehicle moves normally after 5
seconds after shifting into gear, no repair
is necessary. If longer, inspect pump
bushing for wear. Replace pump house.
5. Rear Band Misadjusted. 5. Adjust band.
6. Valve Body Filter Plugged. 6. Replace fluid and filter. If oil pan and
old fluid were full of clutch disc material
and/or metal particles, overhaul will be
necessary.
7. Oil Pump Gears Worn/Damaged. 7. Remove transmission and replace oil
pump.
8. Governor Circuit and Solenoid Valve
Electrical Fault.
8. Test with DRB and repair as required.
9. Hydraulic Pressure Incorrect. 9. Perform pressure test, remove
transmission and repair as needed.
10. Reaction Shaft Seal Rings
Worn/Broken.
10. Remove transmission, remove oil
pump and replace seal rings.
11. Rear Clutch/Input Shaft, Rear Clutch
Seal Rings Damaged.
11. Remove and disassemble
transmission and repair as necessary.
12. Regulator Valve Stuck. 12. Clean.
13. Cooler Plugged. 13. Transfer case failure can plug cooler.
21 - 16 TRANSMISSION AND TRANSFER CASE ZG
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NO DRIVE RANGE (REVERSE OK) 1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable Loose/
Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble
transmission and rear clutch and seals.
Repair/replace worn or damaged parts
as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.
5. Remove and disassemble
transmission. Replace overrunning
clutch.
6. Input Shaft Seal Rings Worn/
Damaged.
6. Remove and disassemble
transmission. Replace seal rings and any
other worn or damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE (VEHICLE
WILL NOT MOVE)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable Loose/
Misadjusted.
2. Inspect, adjust and reassemble
linkage as needed. Replace worn/
damaged parts.
3. U-Joint/Axle/Transfer Case Broken. 3. Perform preliminary inspection
procedure for vehicle that will not move.
Refer to procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble
transmission. Repair or replace failed
components as needed. Replace filter. If
filter and fluid contained clutch material
or metal particles, an overhaul may be
necessary. Perform lube flow test. Flush
oil. Replace cooler as necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly
if necessary.
6. Valve Body Malfunctioned. 6. Check and inspect valve body.
Replace valve body (as assembly) if any
valve or bore is damaged. Clean and
reassemble correctly if all parts are in
good condition.
7. Transmission Internal Component
Damaged.
7. Remove and disassemble
transmission. Repair or replace failed
components as needed.
8. Park Sprag not Releasing - Check
Stall Speed, Worn/Damaged/Stuck.
8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Inspect and replace as required.
ZG TRANSMISSION AND TRANSFER CASE 21 - 17
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
SHIFTS DELAYED OR ERRATIC
(SHIFTS ALSO HARSH AT TIMES)
1. Fluid Level Low/High. 1. Correct fluid level and check for leaks
if low.
2. Fluid Filter Clogged. 2. Replace filter. If filter and fluid
contained clutch material or metal
particles, an overhaul may be necessary.
Perform lube flow test.
3. Throttle Linkage Misadjusted. 3. Adjust linkage as described in service
section.
4. Throttle Linkage Binding. 4. Check cable for binding. Check for
return to closed throttle at transmission.
5. Gearshift Linkage/Cable Misadjusted. 5. Adjust linkage/cable as described in
service section.
6. Clutch or Servo Failure. 6. Remove valve body and air test
clutch, and band servo operation.
Disassemble and repair transmission as
needed.
7. Governor Circuit Electrical Fault. 7. Test using DRB and repair as
required.
8. Front Band Misadjusted. 8. Adjust band.
9. Pump Suction Passage Leak. 9. Check for excessive foam on dipstick
after normal driving. Check for loose
pump bolts, defective gasket. Replace
pump assembly if needed.
NO REVERSE (D RANGES OK) 1. Gearshift Linkage/Cable Misadjusted/
Damaged.
1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Replace overdrive annulus gear.
3. Rear Band Misadjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body.
Replace valve body if any valves or
valve bores are worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble
transmission. Replace worn/damaged
servo parts as necessary.
6. Direct Clutch in Overdrive Worn 6. Disassemble overdrive. Replace worn
or damaged parts.
7. Front Clutch Burnt. 7. Remove and disassemble
transmission. Replace worn, damaged
clutch parts as required.
HAS FIRST/REVERSE ONLY (NO 1-2
OR 2-3 UPSHIFT)
1. Governor Circuit Electrical Fault. 1. Test using DRB and repair as
required.
2. Valve Body Malfunction. 2. Repair stuck 1-2 shift valve or
governor plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
MOVES IN 2ND OR 3RD GEAR,
ABRUPTLY DOWNSHIFTS TO LOW
1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.
2. Governor Valve Sticking. 2. Remove, clean and inspect. Replace
faulty parts.
21 - 18 TRANSMISSION AND TRANSFER CASE ZG
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NO LOW GEAR (MOVES IN 2ND OR
3RD GEAR ONLY)
1. Governor Valve Sticking. 1. Remove governor, clean, inspect and
repair as required.
2. Governor Circuit Electrical Fault. 2. Test with DRB and repair as required.
3. Valve Body Malfunction. 3. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
4. Front Servo Piston Cocked in Bore. 4. Inspect servo and repair as required.
5. Front Band Linkage Malfunction 5. Inspect linkage and look for bind in
linkage.
NO KICKDOWN OR NORMAL
DOWNSHIFT
1. Throttle Linkage Misadjusted. 1. Adjust linkage.
2. Accelerator Pedal Travel Restricted. 2. Verify floor mat is not under pedal,
repair worn accelerator cable or bent
brackets.
3. Valve Body Hydraulic Pressures Too
High or Too Low Due to Valve Body
Malfunction or Incorrect Hydraulic
Control Pressure Adjustments.
3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments
as required.
4. Governor Circuit Electrical Fault. 4. Test with DRB and repair as required.
5. Valve Body Malfunction. 5. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments
as required.
6. TPS Malfunction. 6. Replace sensor, check with DRB scan
tool.
7. PCM Malfunction. 7. Check with DRB II and replace if
required.
8. Valve Body Malfunction. 8. Repair sticking 1-2, 2-3 shift valves,
governor plugs, 3-4 solenoid, 3-4 shift
valve, 3-4 timing valve.
STUCK IN LOW GEAR (WILL NOT
UPSHIFT)
1. Throttle Linkage Misadjusted/Stuck. 1. Adjust linkage and repair linkage if
worn or damaged. Check for binding
cable or missing return spring.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage and repair linkage if
worn or damaged.
3. Governor Component Electrical Fault. 3. Check operating pressures and test
with DRB scan tool, repair faulty
component.
4. Front Band Out of Adjustment. 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of
clutches and bands. Repair faulty
component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Misadjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped. 2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
determine cause and repair as required.
ZG TRANSMISSION AND TRANSFER CASE 21 - 19
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Misassembled. 2. Route cable away from engine and
bell housing.
3. Valve Body Misassembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs
are damaged. Check for loose bolts or
screws.
4. Pump Passages Leaking 4. Check pump for porous casting,
scores on mating surfaces and excess
rotor clearance. Repair as required.
Loose pump bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage.
3. Rear Band Misadjusted. 3. Adjust band.
4. Rear Band Worn. 4. Replace as required.
5. Overdrive Direct Clutch Worn. 5. Disassemble overdrive. Repair as
needed.
6. Hydraulic Pressure Too Low. 6. Perform hydraulic pressure tests to
determine cause.
7. Rear Servo Leaking. 7. Air pressure check clutch-servo
operation and repair as required.
8. Band Linkage Binding. 8. Inspect and repair as required.
SLIPS IN FORWARD DRIVE RANGES 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump
halves and loose pump bolts. Replace
pump if necessary.
3. Throttle Linkage Misadjusted. 3. Adjust linkage.
4. Gearshift Linkage Misadjusted. 4. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to Worn
Pump, Incorrect Control Pressure
Adjustments, Valve Body Warpage or
Malfunction, Sticking, Leaking Seal
Rings, Clutch Seals Leaking, Servo
Leaks, Clogged Filter or Cooler Lines
6. Perform hydraulic and air pressure
tests to determine cause.
7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.
7. Air pressure check clutch-servo
operation and repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR D ONLY, BUT
NO IN 1 POSITION
Overrunning Clutch Faulty. Replace overrunning clutch.
21 - 20 TRANSMISSION AND TRANSFER CASE ZG
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
GROWLING, GRATING OR
SCRAPING NOISES
1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting Dust
Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/Seized. 3. Check for debris in oil pan and repair
as required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil
pan. Repair as required.
5. Oil Pump Components Scored/
Binding.
5. Remove, inspect and repair as
required.
6. Output Shaft Bearing or Bushing
Damaged.
6. Remove, inspect and repair as
required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair
as required.
8. Front and Rear Bands Misadjusted. 8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation
and repair as required.
3. Front or Rear Band Misadjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages
in case.
5. Servo Band or Linkage Malfunction. 5. Air pressure check servo operation
and repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as
required (look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform
flow check. Inspect pump for excessive
side clearance. Replace pump as
required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.
1. Test wiring and connectors with test
lamp and volt/ohmmeter. Repair wiring
as necessary. Replace connectors and/or
harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRB scan
tool. Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRB scan tool at
PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace
solenoid assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace
solenoid if plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup
timing valve.
NO 4-3 DOWNSHIFT WHEN
CONTROL SWITCH IS TURNED OFF
1. Control Switch Open/Shorted. 1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.
2. Test solenoids and replace if seized or
shorted.
3. PCM Malfunction. 3. Test with DRB scan tool. Replace
PCM if faulty.
4. Valve Body Stuck Valves. 4. Repair stuck 3-4, lockup or lockup
timing valve.
ZG TRANSMISSION AND TRANSFER CASE 21 - 21
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
CLUNK NOISE FROM DRIVELINE ON
CLOSED THROTTLE 4-3
DOWNSHIFT
1. Transmission Fluid Low. 1. Add Fluid.
2. Throttle Cable Misadjusted. 2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.
3. Replace overdrive piston thrust plate
spacer.
3-4 UPSHIFT OCCURS
IMMEDIATELY AFTER 2-3 SHIFT
1. Overdrive Solenoid Connector or
Wiring Shorted.
1. Test connector and wiring for loose
connections, shorts or ground and repair
as needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary.
Check with DRB scan tool.
3. PCM Malfunction. 3. Test PCM with DRB scan tool and
replace controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and
inspect valve body components. Make
sure all valves and plugs slide freely in
bores. Polish valves with crocus cloth if
needed.
WHINE/NOISE RELATED TO ENGINE
SPEED
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
NO 3-4 UPSHIFT 1. Dash O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse
failed and repair as necessary (i.e.,
shorts or grounds in circuit).
3. O/D Switch Wire Shorted/Open Cut. 3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.
4. Test both sensors with test lamp or
volt/ohmmeter and replace faulty sensor.
5. TPS Malfunction. 5. Check with DRB scan tool and replace
if necessary.
6. Neutral Switch to PCM Wire
Shorted/Cut.
6. Test switch as described in service
section and replace if necessary. Engine
no start.
7. PCM Malfunction. 7. Check with DRB scan tool and replace
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open
and repair loose or damaged wires (DRB
scan tool).
9. Solenoid Feed Orifice in Valve Body
Blocked.
9. Remove, disassemble, and clean
valve body thoroughly. Check feed
orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to
determine cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4
timing valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and
install correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
21 - 22 TRANSMISSION AND TRANSFER CASE ZG
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
SLIPS IN OVERDRIVE FOURTH
GEAR
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Overdrive Clutch Pack Worn. 2. Remove overdrive unit and rebuild
clutch pack.
3. Overdrive Piston Retainer Bleed
Orifice Blown Out.
3. Disassemble transmission, remove
retainer and replace orifice.
4. Overdrive Piston or Seal Malfunction. 4. Remove overdrive unit. Replace seals
if worn. Replace piston if damaged. If
piston retainer is damaged, remove and
disassemble the transmission.
5. 3-4 Shift Valve, Timing Valve or
Accumulator Malfunction.
5. Remove and overhaul valve body.
Replace accumulator seals. Make sure
all valves operate freely in bores and do
not bind or stick. Make sure valve body
screws are correctly tightened and
separator plates are properly positioned.
6. Overdrive Unit Thrust Bearing Failure. 6. Disassemble overdrive unit and
replace thrust bearing (NO. 1 thrust
bearing is between overdrive piston and
clutch hub; NO. 2 thrust bearing is
between the planetary gear and the
direct clutch spring plate; NO. 3 thrust
bearing is between overrunning clutch
hub and output shaft).
7. O/D Check Valve/Bleed Orifice
Failure.
7. Check for function/secure orifice insert
in O/D piston retainer.
DELAYED 3-4 UPSHIFT (SLOW TO
ENGAGE)
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Throttle Valve Cable Misadjusted. 2. Adjust throttle valve cable.
3. Overdrive Clutch Pack Worn/Burnt. 3. Remove unit and rebuild clutch pack.
4. TPS Faulty. 4. Test with DRB scan tool and replace
TPS.
5. Overdrive Clutch Bleed Orifice
Plugged.
5. Disassemble transmission and replace
orifice.
6. Overdrive Solenoid or Wiring
Shorted/Open.
6. Test solenoid and check wiring for
loose/corroded connections or shorts/
grounds. Replace solenoid if faulty and
repair wiring if necessary.
7. Overdrive Excess Clearance 7. Remove unit. Measure end play and
select proper spacer.
8. O/D Check Valve Missing or Stuck. 8. Check for presence of check valve.
Repair or replace as required.
TORQUE CONVERTER LOCKS UP
IN SECOND AND/OR THIRD GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2, 2-3, 3-4 OR 3-2 SHIFTS Lockup Solenoid Malfunction. Remove valve body and replace
solenoid assembly.
NO START IN PARK OR NEUTRAL 1. Gearshift Linkage/Cable Misadjusted. 1. Adjust linkage/cable.
2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp.
Repair as required.
3. Neutral Switch Faulty. 3. Refer to service section for test and
replacement procedure.
4. Neutral Switch Connect Faulty. 4. Connectors spread open. Repair.
5. Valve Body Manual Lever Assembly
Bent/Worn/Broken.
5. Inspect lever assembly and replace if
damaged.
ZG TRANSMISSION AND TRANSFER CASE 21 - 23
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NO REVERSE (OR SLIPS IN
REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch
pack.
2. Rear Band Misadjusted. 2. Adjust band.
3. Front Clutch Malfunctioned/Burned. 3. Air-pressure test clutch operation.
Remove and rebuild if necessary.
4. Overdrive Thrust Bearing Failure. 4. Disassemble geartrain and replace
bearings.
5. Direct Clutch Spring Collapsed/
Broken.
5. Remove and disassemble unit. Check
clutch position and replace spring.
OIL LEAKS. 1. Speedometer Adapter Leaks. 1. Replace both adapter seals.
2. Fluid Lines and Fittings Loose/Leaks/
Damaged.
2. Tighten fittings. If leaks persist,
replace fittings and lines if necessary.
3. Fill Tube (where tube enters case)
Leaks/Damaged.
3. Replace O-ring seal. Inspect tube for
cracks in fill tube.
4. Pressure Port Plug Loose Loose/
Damaged.
4. Tighten to correct torque. Replace
plug or reseal if leak persists.
5. Pan Gasket Leaks. 5. Tighten pan screws (150 in. lbs.). If
leaks persist, replace gasket.
6. Valve Body Manual Lever Shaft Seal
Leaks/Worn.
6. Replace shaft seal.
7. Rear Bearing Access Plate Leaks. 7. Replace gasket. Tighten screws.
8. Gasket Damaged or Bolts are Loose. 8. Replace bolts or gasket or tighten
both.
9. Adapter/Extension Gasket Damaged
Leaks/Damaged.
9. Replace gasket.
10. Neutral Switch Leaks/Damaged. 10. Replace switch and gasket.
11. Converter Housing Area Leaks. 11. Check for leaks at seal caused by
worn seal or burr on converter hub
(cutting seal), worn bushing, missing oil
return, oil in front pump housing or hole
plugged. Check for leaks past O-ring
seal on pump or past pump-to-case
bolts; pump housing porous, oil coming
out vent due to overfill or leak past front
band shaft access plug.
12. Pump Seal Leaks/Worn/Damaged. 12. Replace seal.
13. Torque Converter Weld Leak/
Cracked Hub.
13. Replace converter.
14. Case Porosity Leaks. 14. Replace case.
NOISY OPERATION IN FOURTH
GEAR ONLY
1. Overdrive Clutch Discs, Plates or
Snap Rings Damaged.
1. Remove unit and rebuild clutch pack.
2. Overdrive Piston or Planetary Thrust
Bearing Damaged.
2. Remove and disassemble unit.
Replace either thrust bearing if
damaged.
3. Output Shaft Bearings Scored/
Damaged.
3. Remove and disassemble unit.
Replace either bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning Clutch
Rollers Worn/Scored.
5. Remove and overhaul overdrive unit.
21 - 24 TRANSMISSION AND TRANSFER CASE ZG
DIAGNOSIS AND TESTING (Continued)
SERVICE PROCEDURES
FLUID LEVEL CHECK
Transmi ssi on fl ui d l evel shoul d be checked monthl y
under normal operati on. I f the vehi cl e i s used for
trai l er towi ng or si mi l ar heavy l oad haul i ng, check
fl ui d l evel and condi ti on weekl y. Fl ui d l evel i s
checked wi th the engi ne runni ng at curb i dl e speed,
the transmi ssi on i n NEUTRAL and the transmi ssi on
fl ui d at normal operati ng temperature.
FLUID LEVEL CHECK PROCEDURE
(1) Transmi ssi on fl ui d must be at normal operat-
i ng temperature for accurate fl ui d l evel check. Dri ve
vehi cl e i f necessary to bri ng fl ui d temperature up to
normal hot operati ng temperature of 82C (180F).
(2) Posi ti on vehi cl e on l evel surface.
(3) Start and run engi ne at curb i dl e speed.
(4) Appl y parki ng brakes.
(5) Shi ft transmi ssi on momentari l y i nto al l gear
ranges. Then shi ft transmi ssi on back to Neutral .
(6) Cl ean top of fi l l er tube and di psti ck to keep
di rt from enteri ng tube.
(7) Remove di psti ck (Fi g. 12) and check fl ui d l evel
as fol l ows:
(a) Correct acceptabl e l evel i s i n crosshatch area.
(b) Correct maxi mum l evel i s to MAX arrow
mark.
(c) I ncorrect l evel i s at or bel ow MI N l i ne.
(d) I f fl ui d i s l ow, add onl y enough Mopar ATF
Pl us to restore correct l evel . Do not overfi l l .
CAUTION: Do not overfill the transmission. Over-
filling may cause leakage out the pump vent which
can be mistaken for a pump seal leak. Overfilling
will also cause fluid aeration and foaming as the
excess fluid is picked up and churned by the gear
train. This will significantly reduce fluid life.
FLUID AND FILTER REPLACEMENT
Refer to the Mai ntenance Schedul es i n Group 0,
Lubri cati on and Mai ntenance, for proper servi ce
i nterval s. The servi ce fl ui d fi l l after a fi l ter change i s
approxi matel y 3.8 l i ters (4.0 quarts).
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(3) Remove bol ts hol di ng front and si des of pan to
transmi ssi on (Fi g. 13).
(4) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
(5) Sl owl y separate front of pan away from trans-
mi ssi on al l owi ng the fl ui d to drai n i nto drai n pan.
(6) Hol d up pan and remove remai ni ng bol t hol d-
i ng pan to transmi ssi on.
(7) Whi l e hol di ng pan l evel , l ower pan away from
transmi ssi on.
(8) Pour remai ni ng fl ui d i n pan i nto drai n pan.
(9) Remove screws hol di ng fi l ter to val ve body
(Fi g. 14).
(10) Separate fi l ter from val ve body and pour fl ui d
i n fi l ter i nto drai n pan.
(11) Di spose of used trans fl ui d and fi l ter properl y.
Fig. 12 Dipstick Fluid Level MarksTypical
DIPSTICK MAXIMUM COR- RECT FLUID LEVEL ACCEPT- ABLE FLUID LEVEL
Fig. 13 Transmission PanTypical
GASKET PAN TRANSMIS- SION
Fig. 14 Transmission FilterTypical
FILTER TRANSMISSION
ZG TRANSMISSION AND TRANSFER CASE 21 - 25
INSPECTION
I nspect bottom of pan and magnet for excessi ve
amounts of metal or fi ber contami nati on. A l i ght
coati ng of cl utch or band materi al on the bottom of
the pan does not i ndi cate a probl em unl ess accompa-
ni ed by sl i ppi ng condi ti on or shi ft l ag. I f fl ui d and
pan are contami nated wi th excessi ve amounts or
debri s, refer to the di agnosi s secti on of thi s group.
Check the adjustment of the front and rear bands,
adjust i f necessary.
CLEANING
(1) Usi ng a sui tabl e sol vent, cl ean pan and magnet
(Fi g. 15).
(2) Usi ng a sui tabl e gasket scraper, cl ean gasket
materi al from gasket surface of transmi ssi on case
and the gasket fl ange around the pan.
INSTALLATION
(1) Pl ace repl acement fi l ter i n posi ti on on val ve body.
(2) I nstal l screws to hol d fi l ter to val ve body (Fi g.
14). Ti ghten screws to 4 Nm (35 i n. l bs.) torque.
(3) Pl ace new gasket i n posi ti on on pan and i nstal l
pan on transmi ssi on.
(4) Pl ace pan i n posi ti on on transmi ssi on.
(5) I nstal l screws to hol d pan to transmi ssi on (Fi g.
13). Ti ghten bol ts to 17 Nm (150 i n. l bs.) torque.
(6) Lower vehi cl e and fi l l transmi ssi on wi th
Mopar ATF Pl us, type 7176 fl ui d.
TRANSMISSION FILL PROCEDURE
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar ATF
Pl us to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 3
pints (1-1/2 quarts) of ATF Pl us to transmi ssi on.
(b) I f transmi ssi on was compl etel y overhaul ed,
torque converter was repl aced or drai ned, and
cool er was fl ushed, add 12 pints (6 quarts) of ATF
Pl us to transmi ssi on.
(3) Appl y parki ng brakes.
(4) Start and run engi ne at normal curb i dl e speed.
(5) Appl y servi ce brakes, shi ft transmi ssi on through
al l gear ranges then back to NEUTRAL, set parki ng
brake, and l eave engi ne runni ng at curb i dl e speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
CONVERTER DRAINBACK CHECK VALVE SERVICE
The converter drai nback check val ve i s l ocated i n
the cool er outl et (pressure) l i ne near the radi ator
l ower tank. The val ve prevents fl ui d drai nback when
the vehi cl e i s parked for l engthy peri ods. The val ve
check bal l i s spri ng l oaded and has an openi ng pres-
sure of approxi matel y 2 psi .
The val ve i s servi ced as an assembl y; i t i s not
repai rabl e. Do not cl ean the val ve i f restri cted, or
contami nated by sl udge, or debri s. I f the val ve fai l s,
or i f a transmi ssi on mal functi on occurs that gener-
ates sl udge and/or cl utch parti cl es and metal shav-
i ngs, the val ve must be repl aced.
The val ve must be removed whenever the cool er
and l i nes are reverse fl ushed. The val ve can be fl ow
tested when necessary. The procedure i s exactl y the
same as for fl ow testi ng a cool er.
I f the val ve i s restri cted, i nstal l ed backwards, or i n
the wrong l i ne, i t wi l l cause an overheati ng condi ti on
and possi bl e transmi ssi on fai l ure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.
OIL COOLER FLOW CHECK
After the new or repai red transmi ssi on has been
i nstal l ed and fi l l ed, the oi l cool er fl ow shoul d be
checked usi ng the fol l owi ng procedure:
Fig. 15 Pan and Magnet
OIL PAN
OIL PAN MAGNET
21 - 26 TRANSMISSION AND TRANSFER CASE ZG
SERVICE PROCEDURES (Continued)
(1) Di sconnect the From cooler l i ne at the trans-
mi ssi on and pl ace a col l ecti ng contai ner under the
di sconnected l i ne.
(2) Run the engi ne at curb i dl e speed, wi th the
shi ft sel ector i n neutral .
(3) I f the fl ui d fl ow i s i ntermi ttent or takes more
than 20 seconds to col l ect one quart, the cool er
shoul d be repl aced.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(4) I f fl ow i s found to be wi thi n acceptabl e l i mi ts,
reconnect the cool er l i ne. Then fi l l transaxl e to the
proper l evel , usi ng the approved type of automati c
transmi ssi on fl ui d.
FLUSHING COOLERS AND TUBES
When a transmi ssi on fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The cool er
bypass val ve i n the transmi ssi on must be repl aced
al so. The torque converter must al so be repl aced.
Thi s wi l l i nsure that metal parti cl es or sl udged oi l
are not l ater transferred back i nto the recondi ti oned
(or repl aced) transmi ssi on.
There are two di fferent procedures for fl ushi ng
cool ers and l i nes. The recommended procedure i s to
use Tool 6906 Cool er Fl usher. The other procedure i s
to use a hand sucti on gun and mi neral spi ri ts.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.11968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906
(1) Remove cover pl ate fi l l er pl ug on Tool 6906.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes. Moni tor pressure readi ngs
and cl ear return l i nes. Pressure readi ngs shoul d sta-
bi l i ze bel ow 20 psi . for vehi cl es equi pped wi th a si n-
gl e cool er and 30 psi . for vehi cl es equi pped wi th dual
cool ers. I f fl ow i s i ntermi ttent or exceeds these pres-
sures, repl ace cool er.
(8) Turn pump OFF.
(9) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(10) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(11) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar type 7176 automati c transmi s-
si on fl ui d.
(12) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(13) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
COOLER FLUSH USING SUCTION GUN AND
MINERAL SPIRITS
(1) Di sconnect the cool er l i nes at the transmi ssi on.
(2) Usi ng a hand sucti on gun fi l l ed wi th mi neral
spi ri ts, reverse fl ush the cool er. Force mi neral spi ri ts
i nto the From Cooler l i ne of the cool er and catch
the exi ti ng spi ri ts from the To Cooler l i ne. Observe
for the presence of debri s i n the exi ti ng fl ui d. Con-
ti nue unti l fl ui d exi ti ng i s cl ear and free from debri s.
(3) Usi ng compressed ai r (under 40 psi .) i n i nter-
mi ttent spurts, bl ow any remai ni ng mi neral spi ri ts
from the cool er, agai n i n the reverse di recti on.
(4) Pump one (1) quart of automati c transmi ssi on
fl ui d through the cool er before reconnecti ng.
(5) I f at any stage of the cl eani ng process, the
cool er does not freel y pass fl ui d, the cool er must be
repl aced.
ZG TRANSMISSION AND TRANSFER CASE 21 - 27
SERVICE PROCEDURES (Continued)
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num tran-
saxl e case and val ve body can be repai red by the use
of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts of
dri l l i ng out the worn-out damaged threads. Then tap
the hol e wi th a speci al Hel i -Coi l tap, or equi val ent,
and i nstal l i ng a Hel i -Coi l i nsert, or equi val ent, i nto
the hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
REMOVAL AND INSTALLATION
TRANSMISSION
The overdri ve uni t can be removed and servi ced
separatel y. I t i s not necessary to remove the enti re
transmi ssi on assembl y to perform overdri ve uni t
repai rs.
I f onl y the overdri ve uni t requi res servi ce, refer to
the overdri ve uni t removal and i nstal l ati on proce-
dures.
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal. Be sure to remove the transmission and
converter as an assembly.
REMOVAL
(1) Di sconnect battery negati ve cabl e.
(2) Di sconnect and l ower or remove necessary
exhaust components.
(3) Remove engi ne-to-transmi ssi on bendi ng braces.
(4) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(5) Remove starter motor.
(6) Di sconnect and remove crankshaft posi ti on sen-
sor. Retai n sensor attachi ng bol ts.
CAUTION: The crankshaft position sensor will be
damaged if the transmission is removed, or
installed, while the sensor is still bolted to the
engine block, or transmission (4.0L only). To avoid
damage, be sure to remove the sensor before
removing the transmission.
(7) Remove torque converter access cover.
(8) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan.
(9) Remove fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube O-ri ng. On 4 x 4
model s, i t wi l l al so be necessary to remove bol t
attachi ng transfer case vent tube to converter hous-
i ng (Fi g. 16).
(10) Mark torque converter and dri ve pl ate for
assembl y al i gnment. Note that bol t hol es i n crank-
shaft fl ange, dri ve pl ate and torque converter al l
have one offset hol e.
(11) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(12) Mark propel l er shaft and axl e yokes for
assembl y al i gnment. Then di sconnect and remove
propel l er shaft. On 4 x 4 model s, remove both propel -
l er shafts.
(13) Di sconnect wi res from park/neutral posi ti on
swi tch, transmi ssi on sol enoi d, and vehi cl e speed sen-
sor.
(14) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever.
(15) Di sconnect throttl e val ve cabl e from transmi s-
si on bracket and throttl e val ve l ever.
(16) On 4 x 4 model s, di sconnect shi ft rod from
transfer case shi ft l ever or remove shi ft l ever from
transfer case.
(17) Di sconnect transmi ssi on fl ui d cool er l i nes at
transmi ssi on fi tti ngs and cl i ps.
(18) Support rear of engi ne wi th safety stand or
jack.
(19) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(20) Remove bol ts securi ng rear support and cush-
i on to transmi ssi on and crossmember. Rai se trans-
mi ssi on sl i ghtl y, sl i de exhaust hanger arm from
bracket and remove rear support.
(21) Remove bol ts attachi ng crossmember to frame
and remove crossmember.
(22) On 4 x 4 model s, remove transfer case.
(23) Remove al l converter housi ng bol ts.
Fig. 16 Fill Tube Attachment
TRANSFER CASE VENT TUBE FILL TUBE (V8) O-RING FILL TUBE (V6)
21 - 28 TRANSMISSION AND TRANSFER CASE ZG
SERVICE PROCEDURES (Continued)
(24) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(25) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(26) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
(27) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
INSTALLATION
(1) Check torque converter hub and hub dri ve
notches for sharp edges burrs, scratches, or ni cks.
Pol i sh the hub and notches wi th 320/400 gri t paper
and crocus cl oth i f necessary. The hub must be
smooth to avoi d damagi ng pump seal at i nstal l ati on.
(2) Lubri cate converter dri ve hub and oi l pump
seal l i p wi th transmi ssi on fl ui d.
(3) Lubri cate converter pi l ot hub wi th transmi s-
si on fl ui d.
(4) Al i gn converter and oi l pump.
(5) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(6) Check converter seati ng wi th steel scal e and
strai ghtedge (Fi g. 17). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(7) Temporari l y secure converter wi th C-cl amp.
(8) Posi ti on transmi ssi on on jack and secure i t
wi th chai ns.
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
(11) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
(12) Rotate converter so al i gnment marks scri bed
on converter are al i gned wi th mark on dri vepl ate.
(13) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft.
(14) I nstal l bol ts attachi ng converter housi ng to
engi ne.
(15) I nstal l rear support. Then l ower transmi ssi on
onto crossmember and i nstal l bol ts attachi ng trans-
mi ssi on mount to crossmember.
(16) Remove engi ne support fi xture.
(17) I nstal l crankshaft posi ti on sensor.
(18) I nstal l vehi cl e speed sensor and speedometer
adapter.
(19) I nstal l new pl asti c retai ner grommet on any
shi ft l i nkage rod or l ever that was di sconnected.
Grommets shoul d not be reused. Use pry tool to
remove rod from grommet and cut away ol d grom-
met. Use pl i ers to snap new grommet i nto l ever and
to snap rod i nto grommet at assembl y.
(20) Connect gearshi ft and throttl e val ve cabl e to
transmi ssi on.
(21) Connect wi res to park/neutral posi ti on swi tch,
transmi ssi on sol enoi d(s) and oxygen sensor. Be sure
transmi ssi on harnesses are properl y routed.
CAUTION: It is essential that correct length bolts
be used to attach the converter to the driveplate.
Bolts that are too long will damage the clutch sur-
face inside the converter.
(22) I nstal l torque converter-to-dri vepl ate bol ts.
Ti ghten bol ts to 31 Nm (270 i n. l bs.).
(23) I nstal l converter housi ng access cover.
(24) I nstal l starter motor and cool er l i ne bracket.
(25) Connect cool er l i nes to transmi ssi on.
(26) I nstal l transmi ssi on fi l l tube. I nstal l new seal
on tube before i nstal l ati on.
(27) I nstal l exhaust components.
(28) I nstal l transfer case.
(29) Al i gn and connect propel l er shaft(s).
(30) Adjust gearshi ft l i nkage and throttl e val ve
cabl e i f necessary.
(31) Lower vehi cl e.
(32) Fi l l transmi ssi on wi th Mopar ATF Pl us, Type
7176 fl ui d.
TORQUE CONVERTER
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
Fig. 17 Typical Method Of Checking
ConverterSeating
SCALE STRAIGHTEDGE
ZG TRANSMISSION AND TRANSFER CASE 21 - 29
REMOVAL AND INSTALLATION (Continued)
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
(1) Lubri cate converter hub and oi l pump seal l i p
wi th transmi ssi on fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
strai ghtedge (Fi g. 18). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
YOKE SEAL REPLACEMENT
REMOVAL
(1) Rai se vehi cl e.
(2) Mark propel l er shaft and axl e yoke for al i gn-
ment reference.
(3) Di sconnect and remove propel l er shaft.
(4) Remove ol d seal wi th Seal Remover C-3985-B
(Fi g. 19) from overdri ve housi ng.
INSTALLATION
(1) Pl ace seal i n posi ti on on overdri ve housi ng.
(2) Dri ve seal i nto overdri ve housi ng wi th Seal
I nstal l er C-3995-A (Fi g. 20).
(3) Careful l y gui de propel l er shaft sl i p yoke i nto
housi ng and onto output shaft spl i nes. Al i gn marks
made at removal and connect propel l er shaft to rear
axl e pi ni on yoke.
Fig. 18 Checking Torque Converter Seating
SCALE STRAIGHTEDGE
Fig. 19 Removing Overdrive Housing Yoke Seal
SPECIAL TOOL C-3985B SEAL
Fig. 20 Installing Overdrive Housing YokeSeal
SPECIAL TOOL C-3995A OR C-3972A SPECIAL TOOL C-4471
21 - 30 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
SPEEDOMETER ADAPTER
Rear axl e gear rati o and ti re si ze determi ne speed-
ometer pi ni on requi rements.
REMOVAL
(1) Rai se vehi cl e.
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 21).
(4) Remove speed sensor and speedometer adapter
as assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 21).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or pi ns are l oose,
severel y corroded, or damaged.
INSTALLATION
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter i f necessary (Fi g. 21).
(3) Lubri cate sensor and adapter O-ri ngs wi th
transmi ssi on fl ui d.
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 Nm
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 22).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 ocl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 Nm (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel i f necessary.
PARK/NEUTRAL POSITION SWITCH
Switc h Replac ement
(1) Rai se vehi cl e and posi ti on drai n pan under
swi tch.
(2) Di sconnect swi tch wi res.
(3) Remove swi tch from case.
(4) Move shi ft l ever to Park and Neutral posi ti ons.
Veri fy that swi tch operati ng l ever fi ngers are cen-
tered i n swi tch openi ng i n case (Fi g. 23).
(5) I nstal l new seal on swi tch and i nstal l swi tch i n
case. Ti ghten swi tch to 34 Nm (25 ft. l bs.) torque.
(6) Test conti nui ty of new swi tch wi th 12V test
l amp.
(7) Connect swi tch wi res and l ower vehi cl e.
(8) Top off transmi ssi on fl ui d l evel .
Fig. 21 Speedometer Pinion Adapter Components
ITEM
TORQUE SENSOR O-RING SPEEDOMETER ADAPTER ADAPTER O-RING SPEEDOMETER PINION ADAPTER CLAMP VEHICLE SPEED SENSOR
ZG TRANSMISSION AND TRANSFER CASE 21 - 31
REMOVAL AND INSTALLATION (Continued)
GEARSHIFT CABLE
REMOVAL
(1) Shi ft transmi ssi on i nto Park.
(2) Remove shi ft l ever bezel and necessary consol e
parts for access to shi ft l ever assembl y.
(3) Di sconnect cabl e at shi ft l ever and feed cabl e
through dash panel openi ng to undersi de of vehi cl e.
(4) Rai se vehi cl e.
(5) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng
bracket. Then remove ol d cabl e from vehi cl e.
INSTALLATION
(1) Route cabl e through hol e i n dash panel . Ful l y
seat cabl e grommet i nto dash panel .
(2) Pl ace the auto transmi ssi on manual shi ft con-
trol l ever i n Park detent (rearmost) posi ti on and
rotate prop shaft to ensure transmi ssi on i s i n park.
(3) Connect shi ft cabl e to shi fter mechani sm by
snappi ng cabl e retai ni ng ears i nto shi fter bracket
and press cabl e end fi tti ng onto l ever bal l stud.
(4) Pl ace the fl oor shi fter l ever i n park posi ti on.
Ensure that the pawl i s seated wi thi n the confi nes of
the adjustment gauge cl i p.
(5) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng ears are engaged and connect cabl e end
fi tti ng onto the manual control l ever bal l stud.
(6) Lock shi ft cabl e i nto posi ti on by pushi ng
upward on the adjusti ng l ock button.
(7) Remove and di scard the shi ft cabl e adjustment
gauge cl i p from the park gate of the shi fter.
BRAKE TRANSMISSION SHIFT INTERLOCK
REMOVAL
(1) Lower the steeri ng col umn.
(2) Remove two screws retai ni ng the i nterl ock
mechani sm to the col umn (Fi g. 24). Unsnap the
mechani sm from col umn.
(3) Remove the center consol e and rel ated tri m.
Refer to Group 23, Body, for proper procedures.
(4) Di sconnect and remove the cabl e from the shi ft
bracket.
(5) Remove the wi re connector at the sol enoi d on
the cabl e
(6) Remove the accel erator pedal (the cabl e routes
under the pedal ). Refer to Group 14, Fuel Systems,
for proper procedures.
(7) Rel ease the cabl e from the accel erator pedal
cl i p.
(8) Remove the carpet as necessary to remove the
cabl e.
INSTALLATION
NOTE: The gearshift cable must be secured into
position and properly adjusted before the installa-
tion of the Brake Transmission Interlock Cable
(BTSI).
(1) Snap the cabl e base assembl y i nto the l arge
square openi ng i n the steeri ng col umn.
(2) Secure the pl asti c base wi th two (2) sel f tap-
pi ng screws (ti ghten upper screw fi rst).
Fig. 22 Index Numbers On Speedometer
PinionAdapter
SPEEDOMETER ADAPTER INDEX NUMBER LOCA- TION
Fig. 23 Park/Neutral Position Switch
NEUTRAL CONTACT
MANUAL LEVER AND SWITCH
PLUNGER IN REVERSE POSI-
TION
PARK CONTACT
SWITCH
21 - 32 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
(3) Snap BTSI cabl e sol enoi d ti e strap i nto hol e i n
steeri ng col umn tube.
(4) Route BTSI cabl e i nto two cl i ps on carpet pad.
(5) Snap el ectri cal connector from brake l i ght
swi tch i nto BTSI cabl e sol enoi d housi ng.
(6) Snap BTSI cabl e adjuster ears i nto fl oor shi fter
bracket and attach cabl e end fi tti ng onto fl oor shi fter
i nterl ock l ever stud.
(7) Remove shi ppi ng pi n from pl asti c base. Then
pl ace fl oor shi fter i n Park posi ti on.
(8) Pl ace the i gni ti on key cyl i nder i n the ACCES-
SORY posi ti on.
(9) Push the cabl e adjuster l ock cl amp downward
to l ock i t.
(10) Remove and di scard the BTSI cabl e nai l head
l ockpi n at steeri ng col umn.
(11) I nstal l the center consol e and rel ated tri m.
Refer to Group 23, Body, for proper procedures.
(12) Test the BTSI cabl e operati on.
GOVERNOR SOLENOID AND PRESSURE SENSOR
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Remove transmi ssi on fl ui d pan and fi l ter.
(3) Di sengage wi re connectors from pressure sen-
sor and sol enoi d (Fi g. 25).
(4) Remove screws hol di ng pressure sol enoi d
retai ner to governor body.
(5) Separate sol enoi d retai ner from governor (Fi g.
26).
(6) Pul l sol enoi d from governor body (Fi g. 27).
(7) Remove bol ts hol di ng governor body to val ve
body.
(8) Separate governor body from val ve body (Fi g.
28).
(9) Remove governor body gasket.
(10) Remove retai ner hol di ng pressure sensor to
governor body.
(11) Pul l pressure sensor from governor body (Fi g.
29).
INSTALLATION
Before i nstal l i ng the pressure sensor and sol enoi d
i n the governor body, repl ace O-ri ng seal s, cl ean the
gasket surfaces and repl ace gasket.
(1) Lubri cate O-ri ng on pressure sensor wi th
transmi ssi on fl ui d.
(2) Al i gn pressure sensor to bore i n governor body
(Fi g. 29).
(3) Push pressure sensor i nto governor body.
(4) I nstal l retai ner to hol d pressure sensor to gov-
ernor body.
(5) Pl ace gasket i n posi ti on on back of governor
body (Fi g. 28).
(6) Pl ace governor body i n posi ti on on val ve body.
(7) I nstal l bol ts to hol d governor body to val ve
body.
(8) Lubri cate O-ri ng, on pressure sol enoi d, wi th
transmi ssi on fl ui d.
(9) Al i gn pressure sol enoi d to bore i n governor
body (Fi g. 27).
(10) Push sol enoi d i nto governor body.
(11) Pl ace sol enoi d retai ner i n posi ti on on governor
(Fi g. 26).
(12) I nstal l screws to hol d pressure sol enoi d
retai ner to governor body.
(13) Engage wi re connectors i nto pressure sensor
and sol enoi d (Fi g. 25).
(14) I nstal l transmi ssi on fl ui d pan and (new) fi l ter.
(15) Lower vehi cl e and road test to veri fy repai r.
Fig. 24 Interlock Mechanism on Column
MOUNTING SCREWS STEERING COLUMN INTERLOCK MECHA- NISM
Fig. 25 Governor Solenoid And Pressure Sensor
PRESSURE SENSOR PRESSURE SOLE- NOID GOVERNOR
ZG TRANSMISSION AND TRANSFER CASE 21 - 33
REMOVAL AND INSTALLATION (Continued)
VALVE BODY
The val ve body can be removed for servi ce wi thout
havi ng to remove the transmi ssi on assembl y.
The val ve body can be di sassembl ed for cl eani ng
and i nspecti on of the i ndi vi dual components. Refer to
Di sassembl y and Assembl y secti on for proper proce-
dures.
The onl y repl aceabl e val ve body components are:
Manual l ever.
Manual l ever washer, seal , E-cl i p, and shaft
seal .
Manual l ever detent bal l .
Throttl e l ever.
Fl ui d fi l ter.
Pressure adjusti ng screw bracket.
Governor pressure sol enoi d.
Governor pressure sensor.
Converter cl utch/overdri ve sol enoi d assembl y
and harness (i ncl udes sump temperature thermi stor).
Governor housi ng gasket.
Sol enoi d case connector O-ri ngs.
The remai ni ng val ve body components are servi ced
onl y as part of a compl ete val ve body assembl y.
REMOVAL
(1) Shi ft transmi ssi on i nto NEUTRAL.
(2) Rai se vehi cl e.
(3) Remove gearshi ft and throttl e l evers from shaft
of val ve body manual l ever.
(4) Di sconnect wi res at sol enoi d case connector
(Fi g. 30).
(5) Posi ti on drai n pan under transmi ssi on oi l pan.
(6) Remove transmi ssi on oi l pan and gasket.
(7) Remove fl ui d fi l ter from val ve body.
(8) Remove bol ts attachi ng val ve body to transmi s-
si on case.
(9) Lower val ve body enough to remove accumul a-
tor pi ston and spri ngs.
(10) Work manual l ever shaft and el ectri cal con-
nector out of transmi ssi on case.
Fig. 26 Pressure Solenoid Retainer
PRESSURE SOLENOID RETAINER GOVERNOR
Fig. 27 Pressure Solenoid and O-ring
PRESSURE SOLENOID O-RING GOVERNOR
Fig. 28 Governor Body and Gasket
GOVERNOR BODY GASKET
Fig. 29 Pressure Sensor and Retainer
RETAINING CLIP GOVERNOR BODY GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID TEMPERATURE THERMISTOR
21 - 34 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
(11) Lower val ve body, rotate val ve body away
from case, pul l park rod out of sprag, and remove
val ve body (Fi g. 31).
INSTALLATION
(1) Check condi ti on of O-ri ng seal s on val ve body
harness connector (Fi g. 32). Repl ace seal s on connec-
tor body i f cut or worn.
(2) Check condi ti on of manual l ever shaft seal i n
transmi ssi on case. Repl ace seal i f l i p i s cut or worn.
I nstal l new seal wi th 15/16 deep wel l socket (Fi g. 33).
(3) Check condi ti on of seal s on accumul ator pi ston
(Fi g. 34). I nstal l new pi ston seal s, i f necessary.
(4) Pl ace val ve body manual l ever i n l ow (1 posi -
ti on) so bal l on park l ock rod wi l l be easi er to i nstal l
i n sprag.
(5) Lubri cate shaft of manual l ever wi th petrol eum
jel l y. Thi s wi l l ease i nserti ng shaft through seal i n
case.
(6) Lubri cate seal ri ngs on val ve body harness con-
nector wi th petrol eum jel l y.
(7) Posi ti on val ve body i n case and work end of
park l ock rod i nto and through pawl sprag. Turn pro-
pel l er shaft to al i gn sprag and park l ock teeth i f nec-
essary. The rod wi l l cl i ck as i t enters pawl . Move rod
to check engagement.
CAUTION: It is possible for the park rod to dis-
place into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into this cavity.
(8) I nstal l accumul ator spri ngs and pi ston i nto
case. Then swi ng val ve body over pi ston and outer
spri ng to hol d i t i n pl ace.
(9) Al i gn accumul ator pi ston and outer spri ng,
manual l ever shaft and el ectri cal connector i n case.
(10) Then seat val ve body i n case and i nstal l one
or two bol ts to hol d val ve body i n pl ace.
(11) Ti ghten val ve body bol ts al ternatel y and
evenl y to 11 Nm (100 i n. l bs.) torque.
(12) I nstal l new fl ui d fi l ter on val ve body. Ti ghten
fi l ter screws to 4 Nm (35 i n. l bs.) torque.
(13) I nstal l throttl e and gearshi ft l evers on val ve
body manual l ever shaft.
(14) Check and adjust front and rear bands i f nec-
essary.
(15) Connect sol enoi d case connector wi res.
(16) I nstal l oi l pan and new gasket. Ti ghten pan
bol ts to 17 Nm (13 ft. l bs.) torque.
(17) Lower vehi cl e and fi l l transmi ssi on wi th
Mopar ATF Pl us, type 7176 fl ui d.
(18) Check and adjust gearshi ft and throttl e val ve
cabl es, i f necessary.
TRANSMISSION COOLER LINE AND FITTINGS
The transmi ssi on cool er l i nes are attached wi th
qui ck connect fi tti ngs (Fi g. 35).
Fig. 30 Transmission Case Connector
SOLENOID CASE
CONNECTOR
PARK/NEU- TRAL POSI- TION SWITCH CONNECTOR TERMINAL
Fig. 31 Valve Body
VALVE BODY WIRE HARNESS GOVERNOR PRESSURE SOLE- NOID PARK ROD GOVERNOR PRESSURE SENSOR
Fig. 32 Valve Body Harness Connector O-RingSeal
CON- NECTOR O-RINGS VALVE BODY HARNESS CON- NECTOR HARNESS
ZG TRANSMISSION AND TRANSFER CASE 21 - 35
REMOVAL AND INSTALLATION (Continued)
The cool er l i nes and fi tti ngs are NOT servi ceabl e.
Damaged fi tti ngs or cool er l i nes are to be repl aced as
assembl i es.
REMOVAL
(1) I f fi tti ng and cool er l i ne are covered wi th di rt,
mud, or grease, cl ean fi tti ng and cool er l i ne wi th
Mopar spray type carburetor or brake cl eaner.
(2) Di sengage retai ner on fi tti ng and pul l cool er
l i ne out of fi tti ng.
(3) Cover open ends of cool er l i nes and fi tti ngs to
prevent di rt entry.
(4) I nspect condi ti on of fi tti ng. Repl ace transmi s-
si on fi tti ng as an assembl y i f fi tti ng body or retai ner
cl i p i s damaged.
INSTALLATION
(1) I f transmi ssi on or radi ator fi tti ngs requi re
repl acement, appl y Mopar Lock N Seal , or equi va-
l ent, to fi tti ng threads before i nstal l ati on.
(2) Wi pe off cool er l i ne and fi tti ng wi th cl ean, dry
cl oth.
(3) I nsert cool er l i ne i nto fi tti ng. Then push l i ne
i nward unti l retai ner secures l i ne. A snap or cl i ck
wi l l be heard and fel t through the l i ne when the
retai ner seats behi nd the cool er l i ne fl ange.
(4) Pul l outward on cool er l i nes to veri fy that they
are properl y secured.
OVERDRIVE UNIT
REMOVAL
(1) Shi ft transmi ssi on i nto Park.
(2) Rai se vehi cl e.
(3) Mark propel l er shaft uni versal joi nt(s) and axl e
pi ni on yoke for al i gnment reference at i nstal l ati on.
(4) Di sconnect and remove propel l er shaft(s).
(5) Remove transmi ssi on oi l pan, remove gasket,
drai n oi l and rei nstal l pan.
(6) I f overdri ve uni t had mal functi oned, or i f fl ui d
i s contami nated, remove enti re transmi ssi on. I f di ag-
nosi s i ndi cated overdri ve probl ems onl y, remove just
the overdri ve uni t.
(7) Support transmi ssi on wi th transmi ssi on jack.
(8) Remove rear crossmember.
(9) Remove vehi cl e speed sensor and speedometer
adapter, i f necessary.
(10) Remove bol ts attachi ng overdri ve uni t to
transmi ssi on (Fi g. 36).
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.
(11) Careful l y work overdri ve uni t off i ntermedi ate
shaft. Do not ti l t uni t duri ng removal . Keep i t as
l evel as possi bl e.
(a) I f overdri ve uni t does not requi re servi ce,
i mmedi atel y i nsert Al i gnment Tool 6227-2 i n
spl i nes of pl anetary gear and overrunni ng cl utch to
prevent spl i nes from rotati ng out of al i gnment. I f
mi sal i gnment occurs, overdri ve uni t wi l l have to be
di sassembl ed i n order to real i gn spl i nes.
(b) I f overdri ve uni t requi res servi ce, refer to
Di sassembl e and Assembl e secti on of thi s group for
proper procedures.
Fig. 33 Manual Lever Shaft Seal
15/16 SOCKET SEAL
Fig. 34 Accumulator Piston Components
INNERSPRING ACCUMULATOR PIS- TON OUTERSPRING SEAL RINGS
Fig. 35 Cooler Line Fitting
PRESSURE LINE QUICK CONNECT FIT- TING QUICK CONNECT FITTING FWD RETURNLINE
21 - 36 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
(12) Remove and retai n overdri ve pi ston thrust
beari ng. Beari ng may remai n on pi ston or i n cl utch
hub duri ng removal .
(13) Posi ti on drai n pan on workbench.
(14) Pl ace overdri ve uni t over drai n pan. Ti l t uni t
to drai n resi dual fl ui d from case.
(15) Exami ne fl ui d for cl utch materi al or metal
fragments. I f fl ui d contai ns these i tems, overhaul wi l l
be necessary.
(16) I f overdri ve uni t does not requi re any servi ce,
l eave al i gnment tool i n posi ti on. Tool wi l l prevent
acci dental mi sal i gnment of pl anetary gear and over-
runni ng cl utch spl i nes.
INSTALLATION
(1) Be sure overdri ve uni t Al i gnment Tool 6227-2
i s ful l y seated before movi ng uni t. I f tool i s not
seated and gear spl i nes rotate out of al i gnment, over-
dri ve uni t wi l l have to be di sassembl ed i n order to
real i gn spl i nes.
(2) I f overdri ve pi ston retai ner was not removed
duri ng servi ce and ori gi nal case gasket i s no l onger
reusabl e, prepare new gasket by tri mmi ng i t.
(3) Cut out ol d case gasket around pi ston retai ner
wi th razor kni fe (Fi g. 37).
(4) Use ol d gasket as templ ate and tri m new gas-
ket to fi t.
(5) Posi ti on new gasket over pi ston retai ner and
on transmi ssi on case. Use petrol eum jel l y to hol d
gasket i n pl ace i f necessary. Do not use any type of
seal er to secure gasket. Use petrol eum jel l y onl y.
(6) I nstal l sel ecti ve spacer on i ntermedi ate shaft, i f
removed. Spacer goes i n groove just rearward of
shaft rear spl i nes (Fi g. 38).
(7) I nstal l thrust beari ng i n overdri ve uni t sl i di ng
hub. Use petrol eum jel l y to hol d beari ng i n posi ti on.
CAUTION: Be sure the shoulder on the inside
diameter of the bearing is facing forward.
(8) Veri fy that spl i nes i n overdri ve pl anetary gear
and overrunni ng cl utch hub are al i gned wi th Al i gn-
ment Tool 6227-2. Overdri ve uni t cannot be i nstal l ed
i f spl i nes are not al i gned. I f spl i nes have rotated out
of al i gnment, uni t wi l l have to be di sassembl ed to
real i gn spl i nes.
(9) Careful l y sl i de Al i gnment Tool 6227-2 out of
overdri ve pl anetary gear and overrunni ng cl utch
spl i nes.
(10) Rai se overdri ve uni t and careful l y sl i de i t
strai ght onto i ntermedi ate shaft. I nsert park rod i nto
park l ock reacti on pl ug at same ti me. Avoi d ti l ti ng
overdri ve duri ng i nstal l ati on as thi s coul d cause
pl anetary gear and overrunni ng cl utch spl i nes to
rotate out of al i gnment. I f thi s occurs, i t wi l l be nec-
essary to remove and di sassembl e overdri ve uni t to
real i gn spl i nes.
(11) Al i gn sl i p-fi t governor tubes and work over-
dri ve uni t forward on i ntermedi ate shaft unti l seated
agai nst transmi ssi on case.
(12) I nstal l bol ts attachi ng overdri ve uni t to trans-
mi ssi on uni t. Ti ghten bol ts i n di agonal pattern to 34
Nm (25 ft-l bs).
(13) I nstal l crossmember.
(14) I nstal l speed sensor and speedometer adapter.
Be sure to i ndex adapter.
Fig. 36 Overdrive Unit Bolts
OVERDRIVE UNIT ATTACHING BOLTS (7)
Fig. 37 Trimming Overdrive Case Gasket
GASKET SHARP KNIFE
Fig. 38 Intermediate Shaft Selective SpacerLocation
SELECTIVE SPACER SPACER GROOVE INTERMEDIATE SHAFT
ZG TRANSMISSION AND TRANSFER CASE 21 - 37
REMOVAL AND INSTALLATION (Continued)
(15) Connect speed sensor and overdri ve wi res.
(16) Al i gn and i nstal l propel l er shaft.
(17) I f val ve body was al so removed, adjust bands,
i nstal l val ve body and i nstal l transmi ssi on oi l pan
and gasket.
OVERDRIVE HOUSING BUSHING
REMOVAL
(1) Remove overdri ve housi ng yoke seal .
(2) I nsert Remover 6957 i nto overdri ve housi ng.
Ti ghten tool to bushi ng and remove bushi ng (Fi g.
39).
INSTALLATION
(1) Al i gn bushi ng oi l hol e wi th oi l sl ot i n overdri ve
housi ng.
(2) Tap bushi ng i nto pl ace wi th I nstal l er 6951 and
Handl e C-4171.
(3) I nstal l new oi l seal i n housi ng usi ng Seal
I nstal l er C-3995A (Fi g. 40).
OUTPUT SHAFT REAR BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e.
(2) Remove overdri ve geartrai n from housi ng.
(3) Remove snap ri ng hol di ng output shaft rear
beari ng i nto overdri ve housi ng (Fi g. 41).
(4) Usi ng a sui tabl e dri ver i nserted through the
rear end of housi ng, dri ve beari ng from housi ng.
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on i n hous-
i ng.
(2) Usi ng a sui tabl e dri ver, dri ve beari ng i nto
housi ng unti l the snap ri ng groove i s vi si bl e.
(3) I nstal l snap ri ng to hol d beari ng i nto housi ng
(Fi g. 41).
(4) I nstal l overdri ve geartrai n i nto housi ng.
(5) I nstal l overdri ve uni t i n vehi cl e.
OUTPUT SHAFT FRONT BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e.
(2) Remove overdri ve geartrai n from housi ng.
(3) Remove snap ri ng hol di ng output shaft front
beari ng to overdri ve geartrai n. (Fi g. 42).
(4) Pul l beari ng from output shaft.
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on on
geartrai n wi th l ocati ng retai ner groove toward the
rear.
(2) Push beari ng onto shaft unti l the snap ri ng
groove i s vi si bl e.
(3) I nstal l snap ri ng to hol d beari ng onto output
shaft (Fi g. 42).
(4) I nstal l overdri ve geartrai n i nto housi ng.
(5) I nstal l overdri ve uni t i n vehi cl e.
Fig. 39 Bushing RemovalTypical
REMOVER 6957 EXTENSION HOUSING BUSHING
Fig. 40 Overdrive Housing Seal Installation
SPECIAL TOOL C-3995A OR C-3972A SPECIAL TOOL C-4471
Fig. 41 Output Shaft Rear Bearing
OUTPUT SHAFT REAR BEARING OVERDRIVE HOUSING SNAPRING
21 - 38 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
DISASSEMBLY AND ASSEMBLY
VALVE BODY
Remove the val ve body from the transmi ssi on,
refer to Removal and I nstal l ati on procedures secti on
i n thi s group.
VALVE BODY MAIN COMPONENT
DISASSEMBLY
CAUTION: Do not clamp any valve body compo-
nent in a vise. This practice can damage the com-
ponent resulting in unsatisfactory operation after
assembly and installation. Do not use pliers to
remove any of the valves, plugs or springs and do
not force any of the components out or into place.
The valves and valve body housings will be dam-
aged if force is used. Tag or mark the valve body
springs for reference as they are removed. Do not
allow them to become intermixed.
(1) Remove fl ui d fi l ter.
(2) Di sconnect wi res from governor pressure sen-
sor and sol enoi d (Fi g. 43).
(3) Remove screws attachi ng governor body and
retai ner pl ate to transfer pl ate (Fi g. 44).
(4) Remove retai ner pl ate, governor body and gas-
ket from transfer pl ate (Fi g. 45).
(5) Di sconnect wi res from governor pressure sen-
sor, i f not done previ ousl y.
(6) Remove governor pressure sensor from gover-
nor body. Sensor i s retai ned i n body wi th M-shaped
spri ng cl i p (Fi g. 46). Remove cl i p wi th smal l poi nted
tool and sl i de sensor out of body.
(7) Remove governor pressure sol enoi d by pul l i ng
i t strai ght out of bore i n governor body (Fi g. 47).
Remove and di scard sol enoi d O-ri ngs i f worn, cut, or
torn.
(8) Remove transmi ssi on fl ui d fi l ter.
(9) Remove smal l shoul der bol t that secures sol e-
noi d harness case connector to 3-4 accumul ator hous-
Fig. 42 Output Shaft Front Bearing
OUTPUT SHAFT FRONT BEARING SNAP RING OUTPUT SHAFT GROOVE TO REAR OVERDRIVE GEARTRAIN
Fig. 43 Governor Pressure Solenoid And
SensorWire Locations
PRESSURE SENSOR PRESSURE SOLE- NOID GOVERNOR
Fig. 44 Governor Body And Retainer PlateAttaching
Screw
PRESSURE SOLENOID RETAINER GOVERNOR
Fig. 45 Governor Body And Gasket
GOVERNOR BODY GASKET
ZG TRANSMISSION AND TRANSFER CASE 21 - 39
i ng (Fi g. 48). Retain shoulder bolt. Either tape it
to harness or thread it back into accumulator
housing after connector removal.
(10) Unhook overdri ve/converter sol enoi d harness
from 3-4 accumul ator cover pl ate (Fi g. 49).
(11) Turn val ve body over and remove screws that
attach overdri ve/converter sol enoi d assembl y to val ve
body (Fi g. 50).
Fig. 46 Governor Pressure Sensor
RETAINING CLIP GOVERNOR BODY GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID TEMPERATURE THERMISTOR
Fig. 47 Governor Pressure Solenoid
PRESSURE SOLENOID O-RING GOVERNOR
Fig. 48 Solenoid Harness Case Connector
ShoulderBolt
SOLENOID HARNESS CASE CONNECTOR 34 ACCUMULA- TOR HOUSING
Fig. 49 Unhooking Solenoid Harness From
AccumulatorCover Plate
OVERDRIVE/CON- VERTER SOLENOID WIRE HARNESS 34 ACCUMULA- TOR COVER PLATE
Fig. 50 Solenoid Assembly Screws
OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY HARNESS
21 - 40 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Remove sol enoi d and harness assembl y from
val ve body (Fi g. 51).
(13) Remove boost val ve cover (Fi g. 52).
(14) Remove boost val ve retai ner, val ve spri ng and
boost val ve (Fi g. 53).
(15) Secure detent bal l and spri ng wi th Retai ner
Tool 6583 (Fi g. 54).
(16) Remove park rod E-cl i p and separate rod from
manual l ever (Fi g. 55).
Fig. 54 Detent Ball And Spring
SPECIAL TOOL 6583 POSI- TIONED ON DETENT HOUS- ING
Fig. 55 Park Rod
MANUAL LEVER E-CLIP PARK ROD
Fig. 51 Solenoid Assembly
CASE CON- NECTOR GOVERNOR SOLENOID WIRES CONVERTER CLUTCH SOLE- NOID SOLENOID SCREWS OVERDRIVE SOLENOID GOVERNOR SENSORWIRES HARNESS
Fig. 52 Boost Valve Cover Location
BOOST VALVE HOUSING AND COVER BOOST VALVE TUBE
Fig. 53 Boost Valve Components
SPRING AND VALVE RETAINER COVER SCREWS BOOST VALVE COVER BOOST VALVE PLUG BOOST VALVE BOOST VALVE SPRING
ZG TRANSMISSION AND TRANSFER CASE 21 - 41
DISASSEMBLY AND ASSEMBLY (Continued)
(17) Remove E-cl i p and washer that retai ns throt-
tl e l ever shaft i n manual l ever (Fi g. 56).
(18) Remove manual l ever and throttl e l ever (Fi g.
57). Rotate and l i ft manual l ever off val ve body and
throttl e l ever shaft. Then sl i de throttl e l ever out of
val ve body.
(19) Posi ti on penci l magnet next to detent housi ng
to catch detent bal l and spri ng. Then careful l y
remove Retai ner Tool 6583 and remove detent bal l
and spri ng (Fi g. 58).
(20) Remove screws attachi ng pressure adjusti ng
screw bracket to val ve body and transfer pl ate (Fi g.
59). Hol d bracket fi rml y agai nst spri ng tensi on whi l e
removi ng l ast screw.
Fig. 56 Throttle Lever E-Clip And Washer
THROTTLE LEVER SHAFT E-CLIP AND WASHER MANUAL SHAFT
Fig. 57 Manual And Throttle Lever
PARK ROD MANUAL LEVER ASSEMBLY THROTTLE LEVER
Fig. 58 Detent Ball And Spring
DETENT HOUS- ING DETENT SPRING DETENT BALL PENCIL MAG- NET
Fig. 59 Adjusting Screw Bracket Fastener
T25 TORX
BIT
REMOVE THESE SCREWS FIRST BRACKET BRACKET REMOVE THIS SCREW LAST
21 - 42 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(21) Remove adjusti ng screw bracket, l i ne pressure
adjusti ng screw, pressure regul ator val ve spri ng and
swi tch val ve spri ng (Fi g. 60). Do not remove throt-
tle pressure adjusting screw from bracket and
do not disturb setting of either adjusting screw
during removal.
(22) Turn upper housi ng over and remove swi tch
val ve, regul ator val ve and spri ng, and manual val ve
(Fi g. 61).
(23) Remove ki ckdown detent, ki ckdown val ve, and
throttl e val ve and spri ng (Fi g. 61).
(24) Loosen l eft-si de 3-4 accumul ator housi ng
attachi ng screw about 2-3 threads. Then remove cen-
ter and ri ght-si de housi ng attachi ng screws (Fi g. 62).
(25) Careful l y rotate 3-4 accumul ator housi ng
upward and remove 3-4 shi ft val ve spri ng and con-
verter cl utch val ve pl ug and spri ng (Fi g. 63).
(26) Remove l eft-si de screw and remove 3-4 accu-
mul ator housi ng from val ve body (Fi g. 64).
(27) Bend back tabs on boost val ve tube brace (Fi g.
65).
(28) Remove boost val ve connecti ng tube (Fi g. 66).
Di sengage tube from upper housi ng port fi rst. Then
rock opposi te end of tube back and forth to work i t
out of l ower housi ng.
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
Fig. 60 Adjusting Screw Bracket And Spring
SWITCH VALVE SPRING LINE PRES- SURE SCREW THROTTLE PRES- SURE ADJUSTING SCREW ADJUSTING SCREWBRACKET PRESSURE REGULA- TOR VALVE SPRING
Fig. 61 Upper Housing Control Valve Locations
UPPER HOUSING REGULATOR VALVE SWITCH VALVEREGULATOR VALVE SPRING KICKDOWNVALVE KICKDOWNDETENT THROTTLE VALVE AND SPRING MANUAL VALVE
12 GOVERNOR PLUG
GOVERNOR PLUG COVER THROTTLE PLUG 23 GOVERNOR PLUG SHUTTLE VALVE PRIMARY SPRING
Fig. 62 Accumulator Housing Screw Locations
34 ACCUMULA- TOR HOUSING
ZG TRANSMISSION AND TRANSFER CASE 21 - 43
DISASSEMBLY AND ASSEMBLY (Continued)
(29) Turn val ve body over so l ower housi ng i s faci ng
upward (Fi g. 67). I n thi s posi ti on, the two check bal l s i n
upper housi ng wi l l remai n i n pl ace and not fal l out
when l ower housi ng and separator pl ate are removed.
(30) Remove screws attachi ng val ve body l ower
housi ng to upper housi ng and transfer pl ate (Fi g.
67). Note position of boost valve tube brace for
assembly reference.
(31) Remove l ower housi ng and overdri ve separa-
tor pl ate from transfer pl ate (Fi g. 67).
(32) Remove transfer pl ate from upper housi ng
(Fi g. 68).
(33) Turn transfer pl ate over so upper housi ng sep-
arator pl ate i s faci ng upward.
(34) Remove upper housi ng separator pl ate from
transfer pl ate (Fi g. 69). Note posi ti on of fi l ter i n sep-
arator pl ate for assembl y reference.
(35) Remove rear cl utch and rear servo check bal l s
from transfer pl ate. Note check bal l l ocati on for
assembl y reference (Fi g. 70).
VALVE BODY UPPER HOUSING DISASSEMBLY
(1) Note l ocati on of check bal l s i n val ve body upper
housi ng (Fi g. 71). Then remove the one l arge di ame-
ter and the si x smal l er di ameter check bal l s.
(2) Remove governor pl ug and shuttl e val ve covers
(Fi g. 73).
Fig. 63 3-4 Shift And Converter Clutch ValveSprings
And Plug
ACCUMULATOR HOUSING CONVERTER CLUTCH VALVE SPRING CLUTCH VALVE PLUG 34 SHIFT VALVE SPRING
Fig. 64 Accumulator Housing, Valve SpringsAnd
Plug
34 SHIFT VALVESPRING CONVERTER CLUTCH VALVE SPRING AND PLUG 34 ACCUMULATOR HOUSING
Fig. 65 Boost Valve Tube Brace
BOOST VALVE TUBE TUBE BRACE (DOUBLE TAB)
Fig. 66 Boost Valve Tube
BOOST VALVE TUBE LOWER HOUS- ING DISENGAGE THIS END OF TUBE FIRST UPPER HOUS- ING
Fig. 67 Lower Housing
21 - 44 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Remove E-cl i p that secures shuttl e val ve sec-
ondary spri ng on val ve stem (Fi g. 72).
(4) Remove throttl e pl ug, pri mary spri ng, shuttl e
val ve, secondary spri ng, and spri ng gui des (Fi g. 73).
(5) Remove boost val ve retai ner, spri ng and val ve
i f not previ ousl y removed.
(6) Remove throttl e pl ug and 1-2 and 2-3 governor
pl ugs (Fi g. 61).
(7) Turn upper housi ng around and remove l i mi t
val ve and shi ft val ve covers (Fi g. 74).
(8) Remove l i mi t val ve housi ng. Then remove
retai ner, spri ng, l i mi t val ve, and 2-3 throttl e pl ug
from l i mi t val ve housi ng (Fi g. 74).
(9) Remove 1-2 shi ft control val ve and spri ng (Fi g. 74).
(10) Remove 1-2 shi ft val ve and spri ng (Fi g. 74).
(11) Remove 2-3 shi ft val ve and spri ng from val ve
body (Fi g. 74).
(12) Remove pressure pl ug cover (Fi g. 74).
(13) Remove l i ne pressure pl ug, sl eeve, throttl e
pressure pl ug and spri ng (Fi g. 74).
Fig. 68 Transfer Plate
UPPER HOUS- ING TRANSFERPLATE
Fig. 69 Upper Housing Separator Plate
TRANSFERPLATE UPPER HOUSING SEPARA- TOR PLATE FILTER SCREEN BRACE
Fig. 70 Rear Clutch And Rear Servo CheckBall Locations
Fig. 71 Check Ball Locations In Upper Housing
SMALL DIAMETER CHECK BALLS (6) LARGE DIAME- TER CHECK BALL (1)
Fig. 72 Shuttle Valve E-Clip And SecondarySpring
Location
E-CLIP SECONDARY SPRING AND GUIDES SHUTTLE VALVE
ZG TRANSMISSION AND TRANSFER CASE 21 - 45
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 73 Shuttle And Boost Valve Components
SPRING RETAINER BOOST VALVE BOOST VALVE PLUG SPRINGGUIDES E-CLIP SHUTTLE VALVE SECONDARYSPRING SHUTTLE VALVE COVER SHUTTLE VALVE SHUTTLE VALVE PRIMARY SPRING GOVERNOR PLUG COVER THROTTLE PLUG UPPER HOUSING BOOST VALVE COVER
Fig. 74 Upper Housing Shift Valve And PressurePlug Locations
UPPER HOUSING 12 SHIFT VALVE AND SPRING 23 SHIFT VALVE AND SPRING23 THROTTLE PLUGLIMIT VALVE HOUSING LIMIT VALVE COVER LIMIT VALVE AND SPRING RETAINER 12 SHIFT CONTROL VALVE AND SPRING PRESSURE PLUG COVER LINE PRESSURE PLUG PLUG SLEEVE THROTTLE PRESSURE SPRING AND PLUG
21 - 46 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
VALVE BODY LOWER HOUSING DISASSEMBLY
(1) Remove ti mi ng val ve cover.
(2) Remove 3-4 ti mi ng val ve and spri ng.
(3) Remove 3-4 qui ck fi l l val ve, spri ng and pl ug.
(4) Remove 3-4 shi ft val ve and spri ng.
(5) Remove converter cl utch val ve, spri ng and pl ug
(Fi g. 75).
(6) Remove converter cl utch ti mi ng val ve, retai ner
and val ve spri ng.
3-4 ACCUMULATOR HOUSING DISASSEMBLY
(1) Remove end pl ate from housi ng.
(2) Remove pi ston spri ng.
(3) Remove pi ston. Remove and di scard pi ston
seal s (Fi g. 76).
VALVE BODY ASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
Fig. 75 Lower Housing Shift Valves And Springs
34 ACCUMULATOR PISTON AND SPRING 34 ACCUMULATOR HOUSING 34 SHIFT VALVE AND SPRING PLUG SPRING RETAINER CONVERTER CLUTCH VALVE AND SPRING CONVERTER CLUTCH TIM- ING VALVE AND SPRING OVERDRIVE SEPARATOR PLATE 34 QUICK FILL SPRING AND VALVE HARNESS CASE CONNECTOR SOLENOID GASKET CONVERTER CLUTCH SOLE- NOID OVERDRIVE SOLENOID TIMING VALVE COVER PLUG 34 TIMING VALVE AND SPRING
Fig. 76 Accumulator Housing Components
ACCUMULATOR PISTON 34 ACCUMULATOR HOUSING TEFLON SEALS PISTON SPRING COVER PLATE AND SCREWS
ZG TRANSMISSION AND TRANSFER CASE 21 - 47
DISASSEMBLY AND ASSEMBLY (Continued)
LOWER HOUSING ASSEMBLY
(1) Lubri cate val ves, spri ngs, and the housi ng
val ve and pl ug bores wi th cl ean transmi ssi on fl ui d
(Fi g. 75).
(2) I nstal l 3-4 ti mi ng val ve spri ng and val ve i n
l ower housi ng.
(3) I nstal l 3-4 qui ck fi l l val ve i n l ower housi ng.
(4) I nstal l 3-4 qui ck fi l l val ve spri ng and pl ug i n
housi ng.
(5) I nstal l ti mi ng val ve end pl ate. Ti ghten end
pl ate screws to 4 Nm (35 i n. l bs.) torque.
3-4 ACCUMULATOR ASSEMBLY
(1) Lubri cate accumul ator pi ston, seal s and hous-
i ng pi ston bore wi th cl ean transmi ssi on fl ui d (Fi g.
76).
(2) I nstal l new seal ri ngs on accumul ator pi ston.
(3) I nstal l pi ston and spri ng i n housi ng.
(4) I nstal l end pl ate on housi ng.
TRANSFER PLATE ASSEMBLY
(1) I nstal l rear cl utch and rear servo check bal l s i n
transfer pl ate (Fi g. 77).
(2) I nstal l fi l ter screen i n upper housi ng separator
pl ate (Fi g. 78).
(3) Al i gn and posi ti on upper housi ng separator
pl ate on transfer pl ate (Fi g. 79).
(4) I nstal l brace pl ate (Fi g. 79). Ti ghten brace
attachi ng screws to 4 Nm (35 i n. l bs.) torque.
(5) I nstal l remai ni ng separator pl ate attachi ng
screws. Ti ghten screws to 4 Nm (35 i n. l bs.) torque.
Fig. 77 Rear Clutch And Rear Servo CheckBall
Locations
REAR CLUTCH CHECK BALL REAR SERVO CHECK BALL TRANSFERPLATE
Fig. 78 Separator Plate Filter Screen Installation
UPPER HOUSING SEPARATORPLATE FILTER SCREEN
Fig. 79 Brace Plate
BRACE TRANSFER PLATE SEPARATOR PLATE
21 - 48 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
UPPER AND LOWER HOUSING ASSEMBLY
(1) Posi ti on upper housi ng so i nternal passages
and check bal l seats are faci ng upward. Then i nstal l
check bal l s i n housi ng (Fi g. 80). Seven check bal l s
are used. The si ngl e l arge check bal l i s approxi -
matel y 8.7 mm (11/32 i n.) di ameter. The remai ni ng 6
check bal l s are approxi matel y 6.3 mm (1/4 i n.) i n
di ameter.
(2) Posi ti on assembl ed transfer pl ate and upper
housi ng separator pl ate on upper housi ng (Fi g. 81).
Be sure fi l ter screen i s seated i n proper housi ng
recess.
(3) Posi ti on l ower housi ng separator pl ate on
transfer pl ate (Fi g. 82).
(4) I nstal l l ower housi ng on assembl ed transfer
pl ate and upper housi ng (Fi g. 83).
(5) I nstal l and start al l val ve body screws by hand
except for the screws to hol d the boost val ve tube
brace. Save those screws for l ater i nstal l ati on. Then
ti ghten screws evenl y to 4 Nm (35 i n. l bs.) torque.
Start at center and work out to si des when ti ghten-
i ng screws (Fi g. 83).
UPPER HOUSING VALVE AND PLUG ASSEMBLY
Refer to (Fi g. 84), (Fi g. 85) and (Fi g. 86) to perform
the fol l owi ng steps.
(1) Lubri cate val ves, pl ugs, spri ngs wi th cl ean
transmi ssi on fl ui d.
(2) Assembl e regul ator val ve l i ne pressure pl ug,
sl eeve, throttl e pl ug and spri ng. I nsert assembl y i n
upper housi ng and i nstal l cover pl ate. Ti ghten cover
pl ate screws to 4 Nm (35 i n. l bs.) torque.
(3) I nstal l 1-2 and 2-3 shi ft val ves and spri ngs.
(4) I nstal l 1-2 shi ft control val ve and spri ng.
(5) I nstal l retai ner, spri ng, l i mi t val ve, and 2-3
throttl e pl ug from l i mi t val ve housi ng.
Fig. 80 Check Ball Locations In Upper Housing
SMALL DIAMETER CHECK BALLS (6) LARGE DIAME- TER CHECK BALL (1)
Fig. 81 Installing Transfer Plate On UpperHousing
Fig. 82 Lower Housing Separator Plate
BE SURE TO ALIGN BORES TRANSFER PLATE LOWER HOUSING (OVERDRIVE) SEPA- RATOR PLATE
Fig. 83 Installing Lower Housing On TransferPlate
And Upper Housing
VALVE BODY SCREWS (13) LOWER HOUS- ING UPPER HOUS- ING TRANSFER PLATE
ZG TRANSMISSION AND TRANSFER CASE 21 - 49
DISASSEMBLY AND ASSEMBLY (Continued)
(6) I nstal l l i mi t val ve housi ng and cover pl ate.
Ti ghten screws to 4 Nm (35 i n. l bs.).
(7) I nstal l shuttl e val ve as fol l ows:
(a) I nsert pl asti c gui des i n shuttl e val ve second-
ary spri ng and i nstal l spri ng on end of val ve.
(b) I nstal l shuttl e val ve i nto housi ng.
(c) Hol d shuttl e val ve i n pl ace.
(d) Compress secondary spri ng and i nstal l E-cl i p
i n groove at end of shuttl e val ve.
(e) Veri fy that spri ng and E-cl i p are properl y
seated before proceedi ng.
(8) I nstal l shuttl e val ve cover pl ate. Ti ghten cover
pl ate screws to 4 Nm (35 i n. l bs.) torque.
(9) I nstal l 1-2 and 2-3 val ve governor pl ugs i n
val ve body.
(10) I nstal l shuttl e val ve pri mary spri ng and
throttl e pl ug.
(11) Al i gn and i nstal l governor pl ug cover. Ti ghten
cover screws to 4 Nm (35 i n. l bs.) torque.
Fig. 84 Shuttle And Boost Valve Components
RETAINER BOOST VALVE BOOST VALVE PLUG SPRINGGUIDES E-CLIP SHUTTLE VALVE SECONDARYSPRING SHUTTLE VALVE COVER SHUTTLE VALVE SHUTTLE VALVE PRIMARY SPRING GOVERNOR PLUG COVER THROTTLE PLUG UPPER HOUSING BOOST VALVE COVER
21 - 50 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 85 Upper Housing Control Valve Locations
Fig. 86 Upper Housing Shift Valve And PressurePlug Locations
ZG TRANSMISSION AND TRANSFER CASE 21 - 51
DISASSEMBLY AND ASSEMBLY (Continued)
BOOST VALVE TUBE AND BRACE ASSEMBLY
(1) Posi ti on val ve body assembl y so l ower housi ng
i s faci ng upward (Fi g. 87).
(2) Lubri cate tube ends and housi ng ports wi th
transmi ssi on fl ui d or petrol eum jel l y.
(3) Start tube i n l ower housi ng port fi rst. Then
swi ng tube downward and work opposi te end of tube
i nto upper housi ng port (Fi g. 87).
(4) I nsert and seat each end of tube i n housi ngs.
(5) Sl i de tube brace under tube and i nto al i gnment
wi th val ve body screw hol es (Fi g. 88).
(6) I nstal l and fi nger ti ghten three screws that
secure tube brace to val ve body housi ngs (Fi g. 88).
(7) Bend tube brace tabs up and agai nst tube to
hol d i t i n posi ti on (Fi g. 89).
(8) Ti ghten al l val ve body housi ng screws to 4 Nm
(35 i n. l bs.) torque after tube and brace are i nstal l ed.
Ti ghten screws i n di agonal pattern starti ng at center
and worki ng outward.
3-4 ACCUMULATOR ASSEMBLY
(1) Posi ti on converter cl utch val ve and 3-4 shi ft
val ve spri ngs i n housi ng (Fi g. 90).
(2) Loosel y attach accumul ator housi ng wi th ri ght-
si de screw (Fi g. 90). I nstal l onl y one screw at thi s
ti me as accumul ator must be free to pi vot upward for
ease of i nstal l ati on.
(3) I nstal l 3-4 shi ft val ve and spri ng.
(4) I nstal l converter cl utch ti mi ng val ve and
spri ng.
(5) Posi ti on pl ug on end of converter cl utch val ve
spri ng. Then compress and hol d spri ngs and pl ug i n
pl ace wi th fi ngers of one hand.
(6) Swi ng accumul ator housi ng upward over val ve
spri ngs and pl ug.
(7) Hol d accumul ator housi ng fi rml y i n pl ace and
i nstal l remai ni ng two attachi ng screws. Be sure
spri ngs and cl utch val ve pl ug are properl y seated
(Fi g. 91). Ti ghten screws to 4 Nm (35 i n. l bs.).
Fig. 87 Boost Valve Tube
BOOST VALVE TUBE LOWER HOUS- ING DISENGAGE THIS END OF TUBE FIRST UPPER HOUS- ING
Fig. 88 Boost Valve Tube And Brace
BOOST VALVE TUBE TUBE BRACE
Fig. 89 Securing Boost Valve Tube With BraceTabs
BEND TABS UP AGAINST TUBE AS SHOWN
Fig. 90 Converter Clutch And 3-4 Shift ValveSprings
RIGHT-SIDE SCREW 34 ACCUMULATOR 34 SHIFT VALVE SPRING CONVERTER CLUTCH VALVE SPRING
21 - 52 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
VALVE BODY FINAL ASSEMBLY AND ADJUSTMENT
(1) I nstal l boost val ve, val ve spri ng, retai ner and
cover pl ate. Ti ghten cover pl ate screws to 4 Nm (35
i n. l bs.) torque.
(2) I nsert manual l ever detent spri ng i n upper
housi ng.
(3) Posi ti on detent bal l on end of spri ng. Then hol d
detent bal l and spri ng i n detent housi ng wi th
Retai ner Tool 6583 (Fi g. 92).
(4) I nstal l throttl e l ever i n upper housi ng. Then
i nstal l manual l ever over throttl e l ever and start
manual l ever i nto housi ng.
(5) Al i gn manual l ever wi th detent bal l and man-
ual val ve. Hol d throttl e l ever upward. Then press
down on manual l ever unti l ful l y seated. Remove
detent bal l retai ner tool after l ever i s seated.
(6) Then I nstal l manual l ever seal , washer and
E-cl i p.
(7) Veri fy that throttl e l ever i s al i gned wi th end of
ki ckdown val ve stem and that manual l ever arm i s
engaged i n manual val ve (Fi g. 93).
(8) Posi ti on l i ne pressure adjusti ng screw i n
adjusti ng screw bracket.
(9) I nstal l spri ng on end of l i ne pressure regul ator
val ve.
(10) I nstal l swi tch val ve spri ng on tang at end of
adjusti ng screw bracket.
(11) I nstal l manual val ve.
(12) I nstal l throttl e val ve and spri ng.
(13) I nstal l ki ckdown val ve and detent.
(14) I nstal l pressure regul ator val ve.
(15) I nstal l swi tch val ve.
(16) Posi ti on adjusti ng screw bracket on val ve
body. Al i gn val ve spri ngs and press bracket i nto
pl ace. I nstal l short, upper bracket screws fi rst and
l ong bottom screw l ast. Veri fy that val ve spri ngs and
bracket are properl y al i gned. Then ti ghten al l three
bracket screws to 4 Nm (35 i n. l bs.) torque.
(17) Lubri cate sol enoi d case connector O-ri ngs and
shaft of manual l ever wi th l i ght coat of petrol eum
jel l y.
(18) Obtai n new fl ui d fi l ter for val ve body but do
not i nstal l fi l ter at thi s ti me.
(19) I f l i ne pressure and/or throttl e pressure
adjustment screw setti ngs were not di sturbed, con-
ti nue wi th overhaul or reassembl y. However, i f
adjustment screw setti ngs were moved or changed,
readjust as descri bed i n Val ve Body Control Pressure
Adjustment procedure.
(20) Attach sol enoi d case connector to 3-4 accumu-
l ator wi th shoul der-type screw. Connector has smal l
l ocati ng tang that fi ts i n di mpl e at top of accumul a-
tor housi ng (Fi g. 94). Seat tang i n di mpl e before
ti ghteni ng connector screw.
(21) I nstal l sol enoi d assembl y and gasket. Ti ghten
sol enoi d attachi ng screws to 8 Nm (72 i n. l bs.)
torque.
(22) Veri fy that sol enoi d wi re harness i s properl y
routed (Fi g. 95). Solenoid harness must be clear
of manual lever and park rod and not be
pinched between accumulator housing and
cover.
Fig. 91 Seating 3-4 Accumulator On LowerHousing
ACCUMULATOR BOX CONVERTER CLUTCH VALVE PLUG
Fig. 92 Detent Ball Spring
SPECIAL TOOL 6583 POSI- TIONED ON DETENT HOUS- ING
Fig. 93 Manual And Throttle Lever Alignment
THROTTLE LEVER MANUAL LEVER VALVE ARM MANUAL VALVE KICKDOWN VALVE
ZG TRANSMISSION AND TRANSFER CASE 21 - 53
DISASSEMBLY AND ASSEMBLY (Continued)
GOVERNOR BODY, SENSOR AND SOLENOID ASSEMBLY
(1) Turn val ve body assembl y over so accumul ator
si de of transfer pl ate i s faci ng down.
(2) I nstal l new O-ri ngs on governor pressure sol e-
noi d and sensor (Fi g. 96).
(3) Lubri cate sol enoi d and sensor O-ri ngs wi th
cl ean transmi ssi on fl ui d.
(4) I nstal l governor pressure sensor i n governor
body. Then secure sensor wi th M-shaped retai ni ng
cl i p (Fi g. 96).
(5) I nstal l governor pressure sol enoi d i n governor
body (Fi g. 97). Push sol enoi d i n unti l i t snaps i nto
pl ace i n body.
(6) Posi ti on governor body gasket on transfer pl ate
(Fi g. 98).
(7) I nstal l retai ner pl ate on governor body and
around sol enoi d (Fi g. 99). Be sure sol enoi d connector
i s posi ti oned i n retai ner cutout.
(8) Al i gn screw hol es i n governor body and trans-
fer pl ate. Then i nstal l and ti ghten governor body
screws to 4 Nm (35 i n. l bs.) torque.
(9) Connect harness wi res to governor pressure
sol enoi d and governor pressure sensor (Fi g. 100).
(10) Perform Li ne Pressure and Throttl e Pressure
adjustments, refer to adjustment secti on of thi s
group for proper procedures.
(11) I nstal l fl ui d fi l ter and pan.
(12) Lower vehi cl e.
(13) Fi l l transmi ssi on wi th recommended fl ui d and
road test vehi cl e to veri fy repai r.
TRANSMISSION
DISASSEMBLY
(1) Cl ean transmi ssi on exteri or wi th steam gun or
wi th sol vent. Wear eye protecti on duri ng cl eani ng
operati ons.
(2) Pl ace transmi ssi on i n a verti cal posi ti on.
(3) Measure and record i nput shaft end pl ay read-
i ngs.
Fig. 94 Solenoid Harness Case Connector
ShoulderBolt
SOLENOID HARNESS CASE CONNECTOR 34 ACCUMULA- TOR HOUSING
Fig. 95 Solenoid Harness Routing
Fig. 96 Governor Pressure Sensor
Fig. 97 Governor Pressure Solenoid
21 - 54 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Remove shi ft and throttl e l evers from val ve
body manual l ever shaft.
(5) Pl ace transmi ssi on i n hori zontal posi ti on.
(6) Remove transmi ssi on oi l pan and gasket.
(7) Remove fi l ter from val ve body (Fi g. 101). Keep
fi l ter screws separate from other val ve body screws.
Fi l ter screws are l onger and shoul d be kept wi th fi l -
ter.
(8) Remove park/neutral posi ti on swi tch.
(9) Remove hex head bol ts attachi ng val ve body to
transmi ssi on case (Fi g. 102). A total of 10 bol ts are
used. Note di fferent bol t l engths for assembl y refer-
ence.
(10) Remove val ve body assembl y. Push val ve body
harness connector out of case. Then work park rod
and val ve body out of case (Fi g. 103).
Fig. 98 Governor Body And Gasket
GOVERNOR BODY GASKET
Fig. 99 Pressure Solenoid Retainer
PRESSURE SOLENOID RETAINER GOVERNOR
Fig. 100 Governor Pressure Sensor And
SolenoidConnectors
PRESSURE SENSOR PRESSURE SOLE- NOID GOVERNOR
Fig. 101 Oil Filter Removal
OIL FILTER VALVE BODY FILTER SCREWS (3)
Fig. 102 Valve Body Bolt Locations
VALVE BODY BOLTS
VALVE BODY
BOLTS
ZG TRANSMISSION AND TRANSFER CASE 21 - 55
DISASSEMBLY AND ASSEMBLY (Continued)
(11) Remove accumul ator pi ston and i nner and
outer spri ngs (Fi g. 104).
(12) Remove pump oi l seal wi th sui tabl e pry tool
or sl i de-hammer mounted screw.
(13) Loosen front band adjusti ng screw l ocknut 4-5
turns. Then ti ghten band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
front/rear cl utches from comi ng out wi th pump and
possi bl y damagi ng cl utch or pump components.
(14) Remove oi l pump bol ts.
(15) Thread bol ts of Sl i de Hammer Tool s C-3752
i nto threaded hol es i n pump body fl ange (Fi g. 105).
(16) Bump sl i de hammer wei ghts outward to
remove pump and reacti on shaft support assembl y
from case (Fi g. 105).
(17) Loosen front band adjusti ng screw unti l band
i s compl etel y l oose.
(18) Squeeze front band together and remove band
strut (Fi g. 106).
Fig. 103 Valve Body Removal
GOVERNOR PRESSURE SENSOR GOVERNOR PRESSURE SOLENOID VALVE BODY PARK ROD ACCUMULATOR PISTON
Fig. 104 Accumulator Piston And Springs
ACCUMULATOR PISTON OUTER SPRING INNER SPRING
Fig. 105 Removing Oil Pump And Reaction
ShaftSupport Assembly
OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY SLIDE HAMMER TOOLS C-3752
Fig. 106 Removing/Installing Front Band Strut
BAND LEVER BAND STRUT
FRONT
BAND
21 - 56 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(19) Remove front band l ever (Fi g. 107).
(20) Remove front band l ever shaft pl ug, i f neces-
sary, from converter housi ng.
(21) Remove front band l ever shaft.
(22) Remove front and rear cl utch uni ts as assem-
bl y. Grasp i nput shaft, hol d cl utch uni ts together and
remove them from case (Fi g. 108).
(23) Li ft front cl utch off rear cl utch (Fi g. 109). Set
cl utch uni ts asi de for overhaul .
(24) Remove i ntermedi ate shaft thrust washer
from front end of shaft or from rear cl utch hub (Fi g.
110).
Fig. 107 Removing/Installing Front Band Lever
FRONT BANDLEVER
Fig. 108 Removing Front/Rear Clutch Assemblies
INPUTSHAFT FRONT CLUTCH REAR CLUTCH
Fig. 109 Separating Front/Rear Clutch Assemblies
FRONTCLUTCH REAR CLUTCH
Fig. 110 Removing Intermediate Shaft ThrustWasher
INPUT SHAFT REAR CLUTCH RETAINER HUB
ZG TRANSMISSION AND TRANSFER CASE 21 - 57
DISASSEMBLY AND ASSEMBLY (Continued)
(25) Remove output shaft thrust pl ate from i nter-
medi ate shaft hub (Fi g. 111).
(26) Sl i de front band off dri vi ng shel l (Fi g. 112)
and remove band from case.
(27) Remove pl anetary geartrai n as assembl y (Fi g.
113). Support geartrai n wi th both hands duri ng
removal . Do not al l ow machi ned surfaces on i nterme-
di ate shaft or overdri ve pi ston retai ner to become
ni cked or scratched.
(28) I f overdri ve uni t i s not to be servi ced, i nstal l
Al i gnment Shaft 6227-2 i nto the overdri ve uni t to
prevent mi sal i gnment of the overdri ve cl utches dur-
i ng servi ce of mai n transmi ssi on components.
(29) Loosen rear band adjusti ng screw 4-5 turns.
(30) Remove l ow-reverse drum snap ri ng (Fi g.
114).
(31) Remove l ow-reverse drum and reverse band.
(32) Remove overrunni ng cl utch rol l er and spri ng
assembl y as a uni t (Fi g. 115).
(33) Compress front servo rod gui de about 1/8 i nch
wi th Val ve Spri ng Compressor C-3422-B (Fi g. 116).
(34) Remove front servo rod gui de snap ri ng.
Exercise caution when removing snap ring.
Fig. 111 Removing Intermediate Shaft ThrustPlate
INTERMEDIATE SHAFT HUB INTERMEDIATE SHAFT THRUST PLATE
Fig. 112 Front Band Removal/Installation
DRIVING SHELL FRONT BAND
Fig. 113 Removing Planetary Geartrain
AndIntermediate Shaft Assembly
PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT ASSEMBLY
Fig. 114 Removing Low-Reverse Drum Snap Ring
LOW-REVERSE DRUM HUB OF OVERDRIVE PIS- TON RETAINER LOW-REVERSE DRUM SNAP RING
21 - 58 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
Servo bore can be scratched or nicked if care is
not exercised.
(35) Remove compressor tool s and remove front
servo rod gui de, spri ng and servo pi ston.
(36) Compress rear servo spri ng retai ner about
1/16 i nch wi th Val ve Spri ng Compressor C-3422-B
(Fi g. 117).
(37) Remove rear servo spri ng retai ner snap ri ng.
Then remove compressor tool s and remove rear servo
spri ng and pi ston.
(38) I nspect transmi ssi on components.
NOTE: TO SERVICE THE OVERRUNNING CLUTCH
CAM OR OVERDRIVE PISTON RETAINER, REFER
TO OVERRUNNING CLUTCH CAM SERVICE IN THIS
SECTION.
ASSEMBLY
Do not al l ow di rt, grease, or forei gn materi al to
enter the case or transmi ssi on components duri ng
assembl y. Keep the transmi ssi on case and compo-
nents cl ean. Al so make sure the tool s and workbench
area used for assembl y operati ons are equal l y cl ean.
Shop towel s used for wi pi ng off tool s and hands
must be made from lint free materi al . Li nt wi l l sti ck
to transmi ssi on parts and coul d i nterfere wi th val ve
operati on, or even restri ct fl ui d passages.
Lubri cate the transmi ssi on components wi th
Mopar transmi ssi on fl ui d duri ng reassembl y. Use
Mopar Door Ease, or Ru-Gl yde on seal s and O-ri ngs
to ease i nstal l ati on.
Petrol eum jel l y can al so be used to hol d thrust
washers, thrust pl ates and gaskets i n posi ti on duri ng
assembl y. However, do not use chassi s grease, bear-
i ng grease, whi te grease, or si mi l ar l ubri cants on any
transmi ssi on part. These types of l ubri cants can
eventual l y bl ock or restri ct fl ui d passages and i nter-
fere wi th val ve operati on. Use petrol eum jel l y onl y.
Do not force parts i nto pl ace. The transmi ssi on
components and subassembl i es are easi l y i nstal l ed by
hand when properl y al i gned.
I f a part seems extremel y di ffi cul t to i nstal l , i t i s
ei ther mi sal i gned or i ncorrectl y assembl ed. Al so ver-
i fy that thrust washers, thrust pl ates and seal ri ngs
are correctl y posi ti oned before assembl y. These parts
can i nterfere wi th proper assembl y i f mi s-posi ti oned.
The pl anetary geartrai n, front/rear cl utch assem-
bl i es and oi l pump are al l much easi er to i nstal l
when the transmi ssi on case i s upri ght.
Fig. 115 Overrunning Clutch Assembly Removal
OVERRUNNING CLUTCH CAM REAR BAND REACTION PIN OVERRUNNING CLUTCH ASSEMBLY
Fig. 116 Compressing Front Servo Rod Guide
SPRING COM- PRESSOR TOOLC-3422B ROD GUIDE SNAPRING
Fig. 117 Compressing Rear Servo Spring
FRONT SERVO SNAP RING
REAR
SERVO
SNAP
RING
SPECIAL TOOL
ZG TRANSMISSION AND TRANSFER CASE 21 - 59
DISASSEMBLY AND ASSEMBLY (Continued)
(1) I nstal l rear servo pi ston, spri ng and retai ner
(Fi g. 118). I nstal l spri ng on top of servo pi ston and
i nstal l retai ner on top of spri ng.
(2) I nstal l front servo pi ston assembl y, servo
spri ng and rod gui de (Fi g. 119).
(3) Compress front/rear servo spri ngs wi th Val ve
Spri ng Compressor C-3422-B and i nstal l each servo
snap ri ng (Fi g. 120).
(4) Lubri cate cl utch cam rol l ers wi th transmi ssi on
fl ui d.
(5) I nstal l rear band i n case (Fi g. 121). Be sure
twi n l ugs on band are seated agai nst reacti on pi n.
(6) I nstal l l ow-reverse drum and check overrun-
ni ng cl utch operati on as fol l ows:
(a) Lubri cate overrunni ng cl utch race (on drum
hub) wi th transmi ssi on fl ui d.
(b) Gui de drum through rear band.
(c) Ti l t drum sl i ghtl y and start race (on drum
hub) i nto overrunni ng cl utch rol l ers.
(d) Press drum rearward and turn i t i n cl ock-
wi se di recti on unti l drum seats i n overrunni ng
cl utch (Fi g. 122).
(e) Turn drum back and forth. Drum should
rotate freely in clockwise direction and lock
in counterclockwise direction (as viewed
from front of case).
Fig. 118 Rear Servo Components
SERVO PISTON PISTON SPRING SNAP RING RETAINER PISTON SEAL
Fig. 119 Front Servo Components
PISTON SEAL RINGS SERVO PISTON SNAP RING ROD GUIDE SPRING ROD
Fig. 120 Compressing Front/Rear Servo Springs
SPRING COM- PRESSOR TOOLC-3422B ROD GUIDE SNAPRING
Fig. 121 Rear Band Installation
REAR BAND
21 - 60 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(7) I nstal l snap ri ng that secures l ow-reverse drum
to hub of overdri ve pi ston retai ner (Fi g. 123).
(8) I nstal l rear band l ever and pi vot pi n (Fi g. 124).
Al i gn l ever wi th pi n bores i n case and push pi vot pi n
i nto pl ace.
(9) I nstal l pl anetary geartrai n assembl y (Fi g. 125.)
Fig. 122 Installing Low-Reverse Drum
REAR
BAND
LOW-REVERSEDRUM
Fig. 123 Installing Low-Reverse Drum
RetainingSnap Ring
LOW-REVERSE DRUM HUB OF OVERDRIVE PIS- TON RETAINER LOW-REVERSE DRUM SNAP RING
Fig. 124 Rear Band Lever And Pivot Pin Installation
REAR BAND LEVER
LEVER
PIVOT
PIN
Fig. 125 Installing Planetary Geartrain
PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT ASSEMBLY
ZG TRANSMISSION AND TRANSFER CASE 21 - 61
DISASSEMBLY AND ASSEMBLY (Continued)
(10) I nstal l thrust pl ate on i ntermedi ate shaft hub
(Fi g. 126). Use petrol eum jel l y to hol d thrust pl ate i n
pl ace.
(11) Check seal ri ng on rear cl utch retai ner hub
and seal ri ngs on i nput shaft (Fi g. 127). Al so veri fy
that shaft seal ri ngs are i nstal l ed i n sequence shown.
(12) I nstal l rear cl utch thrust washer (Fi g. 128).
Use addi ti onal petrol eum jel l y to hol d washer i n
pl ace i f necessary.
(13) Al i gn cl utch di scs i n front cl utch and i nstal l
front cl utch on rear cl utch (Fi g. 129). Rotate front
cl utch retai ner back and forth unti l compl etel y
seated on rear cl utch retai ner.
Fig. 126 Installing Intermediate Shaft ThrustPlate
INTERMEDIATE SHAFT HUB INTERMEDIATE SHAFT THRUST PLATE
Fig. 127 Input Shaft Seal Ring Location
INPUT SHAFTTEFLON SEAL RING METAL SEAL RING REAR CLUTCH RETAINER
Fig. 128 Installing Rear Clutch Thrust Washer
REAR CLUTCH RETAINER REAR CLUTCH THRUST WASHER (FIBER)
Fig. 129 Assembling Front And Rear ClutchUnits
TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED REAR CLUTCH ASSEMBLY
21 - 62 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(14) Coat i ntermedi ate shaft thrust washer wi th
petrol eum jel l y. Then i nstal l washer i n rear cl utch
hub (Fi g. 130). Use enough petrol eum jel l y to hol d
washer i n pl ace. Be sure grooved side of washer
faces rearward (toward output shaft) as shown.
Also note that washer only fits one way in
clutch hub. Note thi ckness of thi s washer. I t i s a
sel ect fi t part and i s used to control transmi ssi on end
pl ay.
(15) Al i gn dri ve teeth on rear cl utch di scs wi th
smal l screwdri ver (Fi g. 131). Thi s makes i nstal l ati on
on front pl anetary easi er.
(16) Rai se front end of transmi ssi on upward as far
as possi bl e and support case wi th wood bl ocks. Front/
rear cl utch and oi l pump assembl i es are easi er to
i nstal l i f transmi ssi on i s as cl ose to upri ght posi ti on
as possi bl e.
(17) Sl i de front band i nto case.
(18) I nstal l front and rear cl utch uni ts as assembl y
(Fi g. 132). Al i gn rear cl utch wi th front annul us gear
and i nstal l assembl y i n dri vi ng shel l . Be sure out-
put shaft thrust washer and thrust plate are
not displaced during installation.
(19) Careful l y work assembl ed cl utches back and
forth to engage and seat rear cl utch di scs on front
annul us gear. Al so be sure front cl utch dri ve l ugs are
ful l y engaged i n sl ots of dri vi ng shel l after i nstal l a-
ti on.
(20) Assembl e front band strut.
(21) I nstal l front band adjuster, strut and adjust-
i ng screw (Fi g. 133).
Fig. 130 Installing Intermediate Shaft ThrustPlate
INTERMEDIATE SHAFT THRUST WASHER INPUT SHAFT REAR CLUTCH RETAINER HUB
Fig. 131 Aligning Rear Clutch Disc Lugs
REAR CLUTCH DISCS USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC TEETH
Fig. 132 Installing Front/Rear Clutch Assemblies
INPUTSHAFT FRONT CLUTCH REAR CLUTCH
Fig. 133 Front Band Linkage Installation
BAND LEVER BAND STRUT FRONTBAND
ZG TRANSMISSION AND TRANSFER CASE 21 - 63
DISASSEMBLY AND ASSEMBLY (Continued)
(22) Ti ghten band adjusti ng screw unti l band just
gri ps cl utch retai ner. Veri fy that front/rear cl utches
are sti l l seated before conti nui ng.
(23) Check seal ri ngs on reacti on shaft support
hub. Veri fy that seal ri ngs are hooked together and
that front cl utch thrust washer i s properl y posi ti oned
(Fi g. 134). Use petrol eum jel l y to hol d thrust washer
i n pl ace i f necessary.
(24) Lubri cate oi l pump body seal wi th petrol eum
jel l y. Lubri cate pump shaft seal l i p wi th petrol eum
jel l y.
(25) Thread two Pi l ot Stud Tool s C-3288-B i nto
bol t hol es i n oi l pump bore fl ange (Fi g. 135).
(26) Al i gn and i nstal l oi l pump gasket (Fi g. 135).
(27) I nstal l oi l pump (Fi g. 136). Al i gn and posi ti on
pump on pi l ot studs. Sl i de pump down studs and
work i t i nto front cl utch hub and case by hand. Then
i nstal l 2 or 3 pump bol ts to hol d pump i n pl ace.
(28) Remove pi l ot stud tool s and i nstal l remai ni ng
oi l pump bol ts. Ti ghten bol ts al ternatel y i n di agonal
pattern to 20 Nm (15 ft. l bs.).
(29) Measure and i f necessary, correct i nput shaft
end pl ay as fol l ows (Fi g. 137):
(a) Attach di al i ndi cator to converter housi ng.
(b) Posi ti on i ndi cator pl unger agai nst i nput
shaft and zero i ndi cator.
(c) Move i nput shaft i n and out and record read-
i ng. End pl ay shoul d be 0.56 - 2.31 mm (0.022 -
0.091 i n.). Proceed to next step i f end pl ay i s not
wi thi n speci fi ed l i mi ts.
(d) I ntermedi ate shaft thrust washer (i n hub of
rear cl utch retai ner) control s end pl ay. Washer i s a
sel ect fi t part and can be changed to adjust end
pl ay. I f end pl ay turns out to be i ncorrect, remove
oi l pump, and cl utches. Then i nstal l thi nner/
thi cker thrust washer as necessary.
(30) I nstal l accumul ator pi ston and i nner and
outer spri ngs (Fi g. 138).
(31) Veri fy that val ve body sol enoi d harness i s
secured i n 3-4 accumul ator housi ng cover pl ate.
(32) I nstal l val ve body as fol l ows:
(a) Al i gn and careful l y i nsert park rod i nto pawl .
Rod wi l l make cl i ck noi se as i t enters pawl . Move
rod sl i ghtl y to check engagement.
(b) Al i gn and seat val ve body on case. Be sure
manual l ever shaft and overdri ve connector are
ful l y seated i n case. Al so be sure val ve body wi ri ng
i s not pi nched or ki nked.
(c) I nstal l and start al l val ve body attachi ng
bol ts by hand. Then ti ghten bol ts evenl y, i n a di ag-
onal pattern to 12 Nm (105 i n. l bs.) torque. Do
Fig. 134 Reaction Shaft Support Seal RingsAnd
Front Clutch Thrust Washer
Fig. 135 Installing Pilot Studs And Oil PumpGasket
OIL PUMP GASKET PILOT STUD TOOLS C-3288B
Fig. 136 Installing Oil Pump Assembly In Case
21 - 64 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
not overtighten valve body bolts. This could
result in distortion and cross leakage after
installation. .
CAUTION: It is possible for the park rod to dis-
place into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity.
(33) I nstal l new fi l ter on val ve body. Ti ghten fi l ter
screws to 4 Nm (35 i n. l bs.).
(34) Adjust front and rear bands.
(35) I nstal l seal on park/neutral posi ti on swi tch
(Fi g. 139). Then i nstal l and ti ghten swi tch to 34 Nm
(25 ft. l bs.).
(36) I nstal l magnet i n oi l pan. Magnet goes on
smal l protrusi on at corner of pan.
(37) Posi ti on new oi l pan gasket on case and
i nstal l oi l pan. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.).
(38) I nstal l new val ve body manual shaft seal i n
case (Fi g. 140). Lubri cate seal l i p and manual shaft
wi th petrol eum jel l y. Start seal over shaft and i nto
case. Seat seal wi th 15/16 i nch, deep wel l socket.
(39) I nstal l throttl e val ve and shi ft sel ector l evers
on val ve body manual l ever shaft.
(40) Cap or cover transmi ssi on openi ngs (cool er
l i ne fi tti ngs, fi l l er tube bore, etc.) to prevent di rt
entry.
(41) I nstal l torque converter. Use C-cl amp or metal
strap to hol d converter i n pl ace for i nstal l ati on.
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON
RETAINER
DISASSEMBLY
NOTE: TO SERVICE THE OVERRUNNING CLUTCH
CAM AND THE OVERDRIVE PISTON RETAINER,
THE TRANSMISSION GEARTRAIN AND OVERDRIVE
UNIT MUST BE REMOVED FROM THE TRANSMIS-
SION.
(1) Remove the overdri ve pi ston (Fi g. 141).
Fig. 137 Measuring Input Shaft End Play
TRANSMIS- SION VENT DIAL INDI- CATOR
Fig. 138 Accumulator Piston And Springs
GOVERNOR PRESSURE SENSOR GOVERNOR PRESSURE SOLENOID VALVE BODY PARK ROD ACCUMULATOR PISTON
Fig. 139 Park/Neutral Position Switch SealPosition
NEUTRAL
SWITCH
SWITCH
SEAL
Fig. 140 Installing Manual Lever Shaft Seal
15/16 SOCKET SEAL
ZG TRANSMISSION AND TRANSFER CASE 21 - 65
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove the overdri ve pi ston retai ner bol ts.
(3) Remove overdri ve pi ston retai ner.
(4) Remove case gasket.
(5) Mark the posi ti on of the overrunni ng cl utch
cam i n the case (Fi g. 142).
(6) Remove the overrunni ng cl utch cam bol ts.
(7) Remove the overrunni ng cl utch cam.
ASSEMBLY
(1) Exami ne bol t hol es i n overrunni ng cl utch cam.
Note that one hol e i s not threaded (Fi g. 143). Thi s
hol e must al i gn wi th bl ank area i n cl utch cam bol t
ci rcl e (Fi g. 144). Mark hol e l ocati on on cl utch cam
and bl ank area i n case wi th grease penci l , pai nt
stri pe, or scri be mark for assembl y reference.
(2) Mark l ocati on of non-threaded hol e i n cl utch
cam and bl ank area i n bol t ci rcl e wi th grease penci l .
(3) Al i gn and i nstal l overrunni ng cl utch and cam
i n case (Fi g. 145). Be sure cam is correctly
installed. Bolt holes in camare slightly counter-
sunk on one side. Be sure this side of cam faces
rearward (toward piston retainer).
(4) Veri fy that non-threaded hol e i n cl utch cam i s
properl y al i gned. Check al i gnment by threadi ng a
Fig. 141 Overdrive Piston Removal
OVERDRIVE CLUTCH PISTON INTERMEDIATESHAFT SELECTIVE SPACER PISTON RETAINER
Fig. 142 Overrunning Clutch Cam Removal
ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN CAM AND CASE OVERRUNNING CLUTCH ASSEMBLY
Fig. 143 Location Of Non-Threaded Hole InClutch
Cam
NON-THREADED HOLE OVERRUNNING CLUTCH CAM
Fig. 144 Location Of Blank Area In ClutchCam Bolt
Circle
OVERRUNNING
CLUTCH CAM
SEAT IN CASE
NON-THREADED HOLE IN CLUTCH CAM ALIGNS HERE (BLANK AREA) OF SEAT
Fig. 145 Overrunning Clutch Installation
ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN CAM AND CASE OVERRUNNING CLUTCH ASSEMBLY
21 - 66 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
bol t i nto each bol t hol e. Adjust cl utch cam posi ti on i f
necessary.
(5) I nstal l and ti ghten overrunni ng cl utch cam
bol ts to 17 Nm (13 ft. l bs.) torque. Note that cl utch
cam bol ts are shorter than pi ston retai ner bol ts.
(6) I nstal l new gasket at rear of transmi ssi on case.
Use petrol eum jel l y to hol d gasket i n pl ace. Be sure
to al i gn governor feed hol es i n gasket wi th feed pas-
sages i n case (Fi g. 146). Al so i nstal l gasket before
overdri ve pi ston retai ner. Center hol e i n gasket i s
smal l er than retai ner and cannot be i nstal l ed over
retai ner.
(7) Posi ti on overdri ve pi ston retai ner on transmi s-
si on case and al i gn bol t hol es i n retai ner, gasket and
case (Fi g. 147). Then i nstal l and ti ghten retai ner
bol ts to 17 Nm (13 ft. l bs.) torque.
(8) I nstal l new seal s on over dri ve pi ston.
(9) Stand transmi ssi on case upri ght on bel l hous-
i ng.
(10) Posi ti on Gui de Ri ng 8114-1 on outer edge of
overdri ve pi ston retai ner.
(11) Posi ti on Seal Gui de 8114-2 on i nner edge of
overdri ve pi ston retai ner.
(12) I nstal l overdri ve pi ston i n overdri ve pi ston
retai ner by: al i gni ng l ocati ng l ugs on overdri ve pi ston
to the two mati ng hol es i n retai ner.
(a) Al i gni ng l ocati ng l ugs on overdri ve pi ston to
the two mati ng hol es i n retai ner.
(b) Lubri cate overdri ve pi ston seal s wi th Mopar
Door Ease, or equi val ent.
(c) I nstal l pi ston over Seal Gui de 81142 and
i nsi de Gui de Ri ng 81141.
(d) Push overdri ve pi ston i nto posi ti on i n
retai ner.
(e) Veri fy that the l ocati ng l ugs entered the l ug
bores i n the retai ner.
NOTE: INSTALL THE REMAINING TRANSMISSION
COMPONENTS AND OVERDRIVE UNIT.
FRONT SERVO PISTON
DISASSEMBLY
(1) Remove seal ri ng from rod gui de (Fi g. 148).
(2) Remove smal l snap ri ng from servo pi ston rod.
Then remove pi ston rod, spri ng and washer from pi s-
ton.
(3) Remove and di scard servo component O-ri ng
and seal ri ngs.
ASSEMBLY
Cl ean and i nspect front servo components.
(1) Lubri cate new O-ri ng and seal ri ngs wi th
petrol eum jel l y and i nstal l them on pi ston, gui de and
rod.
(2) I nstal l rod i n pi ston. I nstal l spri ng and washer
on rod. Compress spri ng and i nstal l snap ri ng (Fi g.
148).
(3) Set servo components asi de for i nstal l ati on dur-
i ng transmi ssi on reassembl y.
Fig. 146 Installing/Aligning Case Gasket
CASE GAS- KET BE SURE GOVER- NOR TUBE FEED HOLES IN CASE AND GASKET ARE ALIGNED
Fig. 147 Aligning Overdrive Piston Retainer
PISTON RETAINER GASKET RETAINER BOLTS
ZG TRANSMISSION AND TRANSFER CASE 21 - 67
DISASSEMBLY AND ASSEMBLY (Continued)
REAR SERVO PISTON
DISASSEMBLY
(1) Remove smal l snap ri ng and remove pl ug and
spri ng from servo pi ston (Fi g. 149).
(2) Remove and di scard servo pi ston seal ri ng.
(3) Lubri cate pi ston and gui de seal s wi th petro-
l eum jel l y. Lubri cate other servo parts wi th Mopar
ATF Pl us transmi ssi on fl ui d.
ASSEMBLY
(1) I nstal l new seal ri ng on servo pi ston.
(2) Assembl e pi ston, pl ug, spri ng and new snap
ri ng.
(3) Lubri cate pi ston seal l i p wi th petrol eum jel l y.
(4) Set servo components asi de for assembl y i nstal -
l ati on.
OIL PUMP AND REACTION SHAFT SUPPORT
DISASSEMBLY
(1) Remove seal ri ng from housi ng and reacti on
shaft support (Fi g. 150).
(2) Mark pump housi ng and support assembl y for
al i gnment reference.
(3) Remove bol ts attachi ng pump body to support
(Fi g. 151).
(4) Separate support from pump housi ng (Fi g.
152).
(5) Remove i nner and outer gears from reacti on
shaft support (Fi g. 153).
Fig. 148 Front Servo
PISTON RINGS SERVO PISTON O-RING SNAP RING PISTON ROD GUIDE SEAL RING SNAP RING SERVO SPRING WASHER SPRING PISTONROD
Fig. 149 Rear Servo Components
SNAPRING PISTON SEAL PISTON PLUG SPRING RETAINER SNAPRING PISTON SPRING CUSHIONSPRING PISTON
Fig. 150 Removing Pump Seal Ring
PUMP HOUSING SEAL RING
Fig. 151 Pump Support Bolts
REACTION SHAFT SUPPORT PUMP
Fig. 152 Separating Pump Housing From
ReactionShaft Support
Fig. 153 Pump Gear Removal
REACTION SHAFT SUP- PORT INNERGEAR OUTERGEAR
21 - 68 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(6) I f pump seal was not removed duri ng transmi s-
si on di sassembl y, remove seal wi th punch and ham-
mer.
(7) Remove front cl utch thrust washer from sup-
port hub (Fi g. 154).
OIL PUMP BUSHING REPLACEMENT
(1) Remove pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng Remover SP-3551 from Tool Set
C-3887-J (Fi g. 155).
(2) I nstal l new pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng I nstal l er SP-5117 (Fi g. 155).
Bushi ng shoul d be fl ush wi th pump housi ng bore.
(3) Stake new pump bushi ng i n two pl aces wi th
bl unt punch (Fi g. 156). Remove burrs from stake
poi nts wi th kni fe bl ade afterward.
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assembl e Bushi ng Remover Tool s SP-1191,
3633 and 5324 (Fi g. 157). Do not clamp any part
of reaction shaft or support in vise.
(2) Hol d Cup Tool SP-3633 fi rml y agai nst reacti on
shaft and thread remover SP-5324 i nto bushi ng as
far as possi bl e by hand. Then thread remover tool 3-4
addi ti onal turns i nto bushi ng wi th a wrench.
(3) Turn remover tool hex nut down agai nst
remover cup to pul l bushi ng from shaft. Cl ean al l
chi ps from shaft after bushi ng removal .
(4) Li ghtl y gri p ol d bushi ng i n vi se or wi th pl i ers
and back remover tool out of bushi ng.
(5) Assembl e Bushi ng I nstal l er Tool s C-4171 and
SP-5325 (Fi g. 157).
(6) Sl i de new bushi ng onto I nstal l er Tool SP-5325.
(7) Posi ti on reacti on shaft support upri ght on a
cl ean smooth surface.
(8) Al i gn bushi ng i n bore. Then tap bushi ng i nto
pl ace unti l Bushi ng I nstal l er SP-5325 bottoms.
(9) Cl ean reacti on shaft support thoroughl y after
i nstal l i ng bushi ng.
Fig. 154 Support Hub Thrust Washer
BUSHING REACTION SHAFT SUPPORT THRUST WASHER HUB
Fig. 155 Removing Oil Pump Bushing
SPECIAL TOOL C-4171 BUSHING REMOVAL SPECIAL TOOL SP-3551 BUSHING SPECIAL TOOL SP-5117 BUSHING BUSHING INSTALLATION SPECIAL TOOL C-4171 PUMP HOUSING
Fig. 156 Staking Oil Pump Bushing
NARROWBLADE
BLUNT PUNCH
TWO STAKES
Fig. 157 Replacing Reaction Shaft SupportBushing
SPECIAL TOOL SP-1191 SPECIAL TOOL SP-3633 SPECIAL TOOL C-4171 SPECIAL TOOL SP-5325 BUSHING INSTALLATION REACTION SHAFT BUSHING REMOVAL SPECIAL TOOL SP-5324 BUSHING
ZG TRANSMISSION AND TRANSFER CASE 21 - 69
DISASSEMBLY AND ASSEMBLY (Continued)
INSPECTION
(1) Cl ean pump and support components wi th sol -
vent and dry them wi th compressed ai r.
(2) Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
(3) I nspect the pump and support components.
Repl ace the pump or support i f the seal ri ng grooves
or machi ned surfaces are worn, scored, pi tted, or
damaged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
(4) I nspect the pump bushi ng. Then check the
reacti on shaft support bushi ng. Repl ace ei ther bush-
i ng onl y i f heavi l y worn, scored or damaged. I t i s not
necessary to repl ace the bushi ngs unl ess they are
actual l y damaged.
(5) I nstal l the gears i n the pump body and mea-
sure pump component cl earances as fol l ows:
(a) Cl earance between outer gear and reacti on
shaft housi ng shoul d be 0.010 to 0.063 mm (0.0004
to 0.0025 i n.). Cl earance between i nner gear and
reacti on shaft housi ng shoul d be 0.025 to 0.177
mm (0.001 to 0.007 i n.). Both cl earances can be
measured at the same ti me by:
(I ) I nstal l i ng the pump gears i n the pump
housi ng.
(I I ) Posi ti on an appropri ate pi ece of Pl asti -
gage across both gears.
(I I I ) Al i gn the pl asti gage to a fl at area on the
reacti on shaft housi ng.
(I V) I nstal l the reacti on shaft to the pump
housi ng.
(V) Separate the reacti on shaft housi ng from
the pump housi ng and measure the Pl asti gage
fol l owi ng the i nstructi ons suppl i ed wi th i t.
(b) Cl earance between i nner gear tooth and
outer gear shoul d be 0.08 to 0.19 mm (0.0035 to
0.0075 i n.). Measure cl earance wi th an appropri ate
feel er gauge.
(c) Cl earance between outer gear and pump
housi ng shoul d al so be 0.010 to 0.19 mm (0.0035 to
0.0075 i n.). Measure cl earance wi th an appropri ate
feel er gauge.
ASSEMBLY
(1) Lubri cate gear bore i n pump housi ng wi th
transmi ssi on fl ui d.
(2) Lubri cate pump gears wi th transmi ssi on fl ui d.
(3) Support pump housi ng on wood bl ocks (Fi g.
158).
(4) I nstal l outer gear i n pump housi ng (Fi g. 158).
Gear can be i nstal l ed ei ther way (i t i s not a one-way
fi t).
(5) I nstal l pump i nner gear (Fi g. 159).
CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter
(I.D.) is chamfered. Be sure the chamfered side
faces forward (to front of pump).
(6) I nstal l new thrust washer on hub of reacti on
shaft support. Lubri cate washer wi th transmi ssi on
fl ui d or petrol eum jel l y.
(7) I f reacti on shaft seal ri ngs are bei ng repl aced,
i nstal l new seal ri ngs on support hub (Fi g. 160).
Lubri cate seal ri ngs wi th transmi ssi on fl ui d or petro-
l eum jel l y after i nstal l ati on. Squeeze each ri ng unti l
ri ng ends are securel y hooked together.
CAUTION: The reaction shaft support seal rings
will break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.
(8) I nstal l reacti on shaft support on pump housi ng
(Fi g. 161).
Fig. 158 Supporting Pump And Installing OuterGear
OUTER GEAR PUMP HOUSING WOOD BLOCKS
Fig. 159 Pump Inner Gear Installation
OUTERGEAR INNERGEAR
21 - 70 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(9) Al i gn reacti on support on pump housi ng. Use
al i gnment marks made at di sassembl y. Or, rotate
support unti l bol t hol es i n support and pump housi ng
are al l al i gned (hol es are offset for one-way fi t).
(10) I nstal l al l bol ts that attach support to pump
housi ng. Then ti ghten bol ts fi nger ti ght.
(11) Ti ghten support-to-pump bol ts to requi red
torque as fol l ows:
(a) Reverse pump assembl y and i nstal l i t i n
transmi ssi on case. Posi ti on pump so bol ts are fac-
i ng out and are accessi bl e.
(b) Secure pump assembl y i n case wi th 2 or 3
bol ts, or wi th pi l ot studs.
(c) Ti ghten support-to-pump bol ts to 20 Nm (15
ft. l bs.).
(d) Remove pump assembl y from transmi ssi on
case.
(12) I nstal l new oi l seal i n pump wi th Speci al Tool
C-4193 and Tool Handl e C-4171 (Fi g. 162). Be sure
seal l i p faces i nward.
(13) I nstal l new seal ri ng around pump housi ng.
Be sure seal i s properl y seated i n groove.
(14) Lubri cate l i p of pump oi l seal and O-ri ng seal
wi th transmi ssi on fl ui d.
FRONT CLUTCH
NOTE: The 42RE transmission uses four plates and
discs for the front clutch. The 44RE uses five plates
and discs for the front clutch. The front clutch
retainer is not interchangeable between these trans-
missions.
Fig. 160 Hub Seal Ring Position
SEAL RINGS SUPPORTHUB
Fig. 161 Assembling Reaction Shaft SupportAnd
Pump Housing
PUMP HOUS- ING REACTION SHAFT SUP- PORT
Fig. 162 Pump Oil Seal Installation
PUMP BODY PUMP SEAL SPECIAL TOOL C-4193
ZG TRANSMISSION AND TRANSFER CASE 21 - 71
DISASSEMBLY AND ASSEMBLY (Continued)
DISASSEMBLY
(1) Remove waved snap ri ng and remove pressure
pl ate, cl utch pl ates and cl utch di scs (Fi g. 163).
(2) Compress cl utch pi ston spri ng wi th Compressor
Tool C-3575-A (Fi g. 164). Be sure l egs of tool are
seated squarel y on spri ng retai ner before compress-
i ng spri ng.
(3) Remove retai ner snap ri ng and remove com-
pressor tool .
(4) Remove spri ng retai ner and cl utch spri ng. Note
posi ti on of retai ner on spri ng for assembl y reference.
(5) Remove cl utch pi ston from cl utch retai ner.
Remove pi ston by rotati ng i t up and out of retai ner.
(6) Remove seal s from cl utch pi ston and cl utch
retai ner hub. Di scard both seal s as they are not reus-
abl e.
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal s on pi ston and i n hub of
retai ner. Be sure l i p of each seal faces i nteri or of
cl utch retai ner.
(3) Lubri cate l i ps of pi ston and retai ner seal s wi th
l i beral quanti ty of Mopar Door Ease. Then l ubri cate
retai ner hub, bore and pi ston wi th l i ght coat of trans-
mi ssi on fl ui d.
(4) I nstal l cl utch pi ston i n retai ner (Fi g. 165). Use
twi sti ng moti on to seat pi ston i n bottom of retai ner.
Fig. 163 42RE Front Clutch Components
RETAINER HUB SEAL CLUTCH PISTON PISTON SPRING SPRING RETAINER SNAP RING CLUTCH DISCS PRESSUREPLATE SNAP RING (WAVED) CLUTCH PLATES SPRING RETAINER PISTON SEAL FRONT CLUTCH RETAINER
Fig. 164 Compressing Front Clutch Piston Spring
FRONT CLUTCH SPRING COMPRESSOR TOOL C-3575A RETAINER SNAP RING SPRING RETAINER
21 - 72 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
CAUTION: Never push the clutch piston straight
in. This will fold the seals over causing leakage and
clutch slip.
(5) Posi ti on spri ng i n cl utch pi ston (Fi g. 166).
(6) Posi ti on spri ng retai ner on top of pi ston spri ng
(Fi g. 167). Make sure retainer is properly
installed. Small raised tabs should be facing
upward. Semicircular lugs on underside of
retainer are for positioning retainer in spring.
(7) Compress pi ston spri ng and retai ner wi th Com-
pressor Tool C-3575-A (Fi g. 164). Then i nstal l new
snap ri ng to secure spri ng retai ner and spri ng.
(8) I nstal l cl utch pl ates and di scs (Fi g. 163).
I nstal l steel pl ate then di sc unti l al l pl ates and di scs
are i nstal l ed. The front cl utch uses 4 cl utch di scs and
pl ates i n a 42RE transmi ssi on. I n a 44RE transmi s-
si on 5 di scs and pl ates are used.
(9) I nstal l pressure pl ate and waved snap ri ng
(Fi g. 163).
Front cl utch cl earance speci fi cati ons for the 42RE
and 44RE transmi ssi on are the same.
Cl earance shoul d be 1.70 to 3.40 mm (0.067 to
0.134 i n.). I f cl earance i s i ncorrect, cl utch di scs,
pl ates, pressure pl ates and snap ri ng may have to be
changed.
Fig. 165 Front Clutch Piston Installation
CLUTCH PIS- TON FRONT CLUTCH RETAINER
Fig. 166 Clutch Piston Spring Installation
RETAINER CLUTCH SPRING PISTON
Fig. 167 Correct Spring RetainerInstalled Position
SMALL TABS ON RETAINER FACE UPWARD
ZG TRANSMISSION AND TRANSFER CASE 21 - 73
DISASSEMBLY AND ASSEMBLY (Continued)
REAR CLUTCH
DISASSEMBLY
(1) Remove fi ber thrust washer from forward si de
of cl utch retai ner.
(2) Remove i nput shaft front/rear seal ri ngs.
(3) Remove sel ecti ve cl utch pack snap ri ng (Fi g.
168).
(4) Remove top pressure pl ate, cl utch di scs, steel
pl ates, bottom pressure pl ate and wave snap ri ng
and wave spri ng (Fi g. 168).
(5) Remove cl utch pi ston wi th rotati ng moti on.
(6) Remove and di scard pi ston seal s.
(7) Remove i nput shaft snap-ri ng (Fi g. 169). I t
may be necessary to press the i nput shaft i n sl i ghtl y
to rel i eve tensi on on the snap-ri ng
(8) Press i nput shaft out of retai ner wi th shop
press and sui tabl e si ze press tool . Use a sui tabl y
si zed press tool to support the retai ner as cl ose to the
i nput shaft as possi bl e.
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal ri ngs on cl utch retai ner hub
and i nput shaft i f necessary (Fi g. 170).
(a) Be sure cl utch hub seal ri ng i s ful l y seated i n
groove and i s not twi sted.
(3) Lubri cate spl i ned end of i nput shaft and cl utch
retai ner wi th transmi ssi on fl ui d. Then press i nput
shaft i nto retai ner. Use a sui tabl y si zed press tool to
support retai ner as cl ose to i nput shaft as possi bl e.
(4) I nstal l i nput shaft snap-ri ng (Fi g. 169).
(5) I nvert retai ner and press i nput shaft i n oppo-
si te di recti on unti l snap-ri ng i s seated.
Fig. 168 Rear Clutch Components
PISTON SPRING REAR CLUTCH PISTON CLUTCH PIS- TON SEALS OUTPUT SHAFT THRUST WASHER(METAL) INPUT SHAFT SNAP RING REAR CLUTCH RETAINER INPUT SHAFT REAR CLUTCH THRUST WASHER(FIBER) SHAFT FRONT SEAL RING (TEFLON) SHAFT REAR SEAL RING(METAL) CLUTCH PACK SNAP RING (SELECTIVE) RETAINER SEAL RING CLUTCH PLATES (3) TOP PRESSURE PLATE CLUTCH DISCS (4) BOTTOM PRESSURE PLATE WAVE SPRING
Fig. 169 Removing/Installing Input Shaft Snap-Ring
REAR CLUTCH RETAINER
INPUT
SHAFT
SNAP
RING
SNAP RING PLIERS
21 - 74 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(6) I nstal l new seal s on cl utch pi ston. Be sure l i p
of each seal faces i nteri or of cl utch retai ner.
(7) Lubri cate l i p of pi ston seal s wi th generous
quanti ty of Mopar Door Ease. Then l ubri cate
retai ner hub and bore wi th l i ght coat of transmi ssi on
fl ui d.
(8) I nstal l cl utch pi ston i n retai ner. Use twi sti ng
moti on to seat pi ston i n bottom of retai ner. A thi n
stri p of pl asti c (about 0.020 thi ck), can be used to
gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight
in. This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) I nstal l pi ston spri ng i n retai ner and on top of
pi ston (Fi g. 173). Concave si de of spri ng faces down-
ward (toward pi ston).
(10) I nstal l wave spri ng i n retai ner (Fi g. 173). Be
sure spri ng i s compl etel y seated i n retai ner groove.
(11) I nstal l bottom pressure pl ate (Fi g. 168).
Ri dged si de of pl ate faces downward (toward pi ston)
and fl at si de toward cl utch pack.
(12) I nstal l fi rst cl utch di sc i n retai ner on top of
bottom pressure pl ate. Then i nstal l a cl utch pl ate fol -
l owed by a cl utch di sc unti l enti re cl utch pack i s
i nstal l ed (4 di scs and 3 pl ates are requi red) (Fi g.
168).
(13) I nstal l top pressure pl ate.
(14) I nstal l sel ecti ve snap ri ng. Be sure snap ri ng
i s ful l y seated i n retai ner groove.
(15) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pack cl earance (Fi g. 174).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 174).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and rel ease i t.
(c) Zero the di al i ndi cator.
Fig. 170 Rear Clutch Retainer And Input ShaftSeal
Ring Installation
REAR CLUTCH RETAINER HUB SEAL RING INPUT SHAFT SEAL RINGS
Fig. 171 Input Shaft Seal Ring Identification
BE SURE RING ENDS ARE HOOKED TOGETHER AFTER INSTALLATION METAL REAR SEAL RING TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTAL- LATION FOR BETTER FIT)
Fig. 172 Pressing Input Shaft Into Rear
ClutchRetainer
INPUT SHAFT REAR CLUTCH RETAINER PRESS RAM
ZG TRANSMISSION AND TRANSFER CASE 21 - 75
DISASSEMBLY AND ASSEMBLY (Continued)
(d) Li ft the pressure pl ate unti l i t contacts the
snap-ri ng and record the di al i ndi cator readi ng.
Cl earance shoul d be 0.64 - 1.14 mm (0.025 - 0.045
i n.). I f cl earance i s i ncorrect, steel pl ates, di scs, sel ec-
ti ve snap ri ng and pressure pl ates may have to be
changed.
The sel ecti ve snap ri ng thi cknesses are:
.107.109 i n.
.098.100 i n.
.095.097 i n.
.083.085 i n.
.076.078 i n.
.071.073 i n.
.060.062 i n.
(16) Coat rear cl utch thrust washer wi th petro-
l eum jel l y and i nstal l washer over i nput shaft and
i nto cl utch retai ner (Fi g. 175). Use enough petrol eum
jel l y to hol d washer i n pl ace.
(17) Set rear cl utch asi de for i nstal l ati on duri ng
fi nal assembl y.
Fig. 173 Piston Spring/Wave Spring Position
REAR CLUTCH RETAINER PISTON SPRING WAVE SPRING CLUTCH PISTON
Fig. 174 Checking Rear Clutch Pack Clearance
DIAL INDICATOR PRESSURE PLATE SNAP RING STAND REAR CLUTCH GAUGE BAR
Fig. 175 Installing Rear Clutch Thrust Washer
REAR CLUTCH RETAINER REAR CLUTCH THRUST WASHER
21 - 76 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
PLANETARY GEARTRAIN/OUTPUT SHAFT
DISASSEMBLY
(1) Remove pl anetary snap ri ng (Fi g. 176).
(2) Remove front annul us and pl anetary assembl y
from dri vi ng shel l (Fi g. 176).
(3) Remove snap ri ng that retai ns front pl anetary
gear i n annul us gear (Fi g. 177).
(4) Remove tabbed thrust washer and tabbed
thrust pl ate from hub of front annul us (Fi g. 178).
(5) Separate front annul us and pl anetary gears
(Fi g. 178).
(6) Remove front pl anetary gear front thrust
washer from annul us gear hub.
(7) Separate and remove dri vi ng shel l , rear pl ane-
tary and rear annul us from output shaft (Fi g. 179).
(8) Remove front pl anetary rear thrust washer
from dri vi ng shel l .
(9) Remove tabbed thrust washers from rear pl an-
etary gear.
(10) Remove l ock ri ng that retai ns sun gear i n
dri vi ng shel l . Then remove sun gear, spacer and
thrust pl ates.
Fig. 176 Front Annulus And Planetary AssemblyRemoval
DRIVINGSHELL FRONT ANNULUS AND PLANETARY ASSEMBLYPLANETARY SNAP RING
Fig. 177 Front Planetary Snap Ring Removal
FRONT ANNU- LUS GEAR PLANETARY SNAP RING
Fig. 178 Front Planetary And Annulus
GearDisassembly
FRONT ANNU- LUS THRUST WASHER THRUSTPLATE FRONT THRUST WASHER FRONT PLANE- TARY
Fig. 179 Removing Driving Shell, Rear PlanetaryAnd
Rear Annulus
REAR ANNU- LUS REAR PLANE- TARY DRIVING SHELL OUTPUTSHAFT
ZG TRANSMISSION AND TRANSFER CASE 21 - 77
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Lubri cate output shaft and pl anetary compo-
nents wi th transmi ssi on fl ui d. Use petrol eum jel l y to
l ubri cate and hol d thrust washers and pl ates i n posi -
ti on.
(2) Assembl e rear annul us gear and support i f di s-
assembl ed. Be sure support snap ri ng i s seated and
that shoul der-si de of support faces rearward (Fi g.
181).
(3) I nstal l rear thrust washer on rear pl anetary
gear (Fi g. 180). Use enough petrol eum jel l y to hol d
washer i n pl ace. Al so be sure al l four washer tabs are
properl y engaged i n gear sl ots.
(4) I nstal l rear annul us over and onto rear pl ane-
tary gear (Fi g. 181).
(5) I nstal l assembl ed rear pl anetary and annul us
gear on output shaft (Fi g. 182). Veri fy that assembl y
i s ful l y seated on shaft.
(6) I nstal l front thrust washer on rear pl anetary
gear (Fi g. 183). Use enough petrol eum jel l y to hol d
washer on gear. Be sure al l four washer tabs are
seated i n sl ots.
(7) I nstal l spacer on sun gear (Fi g. 184).
(8) I nstal l thrust pl ate on sun gear (Fi g. 185). Note
that dri vi ng shel l thrust pl ates are i nterchangeabl e.
Use ei ther pl ate on sun gear and at front/rear of
shel l .
(9) Hol d sun gear i n pl ace and i nstal l thrust pl ate
over sun gear at rear of dri vi ng shel l (Fi g. 186).
(10) Posi ti on wood bl ock on bench and support sun
gear on bl ock (Fi g. 187). Thi s makes i t easi er to al i gn
and i nstal l sun gear l ock ri ng. Keep wood bl ock
handy as i t wi l l al so be used for geartrai n end pl ay
check.
Fig. 180 Planetary Geartrain Components
SELECT FIT PLAN- ETARY SNAPRING FRONT ANNULUS SNAP RING SUPPORT SNAP RING ANNULUS GEAR SUP- PORTTHRUSTPLATE FRONT ANNU- LUS GEAR FRONT PLAN- ETARY THRUST WASHERS (4 TAB) SUNGEAR SUN GEAR SPACER
DRIVING SHELL FRONT
THRUST PLATE
DRIVING SHELL FRONT PLANE- TARY GEAR LOW-REVERSE DRUM SUPPORT SNAP RING REAR PLANETARY GEAR ANNULUS GEAR SUPPORT REAR ANNU- LUS GEAR REAR PLANETARY THRUST WASHERS (4 TAB) SUN GEAR LOCK RING OUTPUT SHAFT (4 X 2 VERSION) OUTPUT SHAFT THRUST PLATE DRIVING SHELL REAR THRUST PLATE FRONT ANNULUS THRUST WASHER
Fig. 181 Assembling Rear Annulus And
PlanetaryGear
REAR ANNULUS GEAR TABBED THRUST WASHER REAR PLANETARY
21 - 78 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(11) Al i gn rear thrust pl ate on dri vi ng shel l and
i nstal l sun gear l ock ri ng. Be sure ri ng i s ful l y seated
i n sun gear ri ng groove (Fi g. 188).
(12) I nstal l assembl ed dri vi ng shel l and sun gear
on output shaft (Fi g. 189).
(13) I nstal l rear thrust washer on front pl anetary
gear (Fi g. 190). Use enough petrol eum jel l y to hol d
washer i n pl ace and be sure al l four washer tabs are
seated.
Fig. 182 Installing Rear Annulus And PlanetaryOn
Output Shaft
REAR ANNULUS AND PLAN- ETARY GEAR ASSEMBLY OUTPUT SHAFT
Fig. 183 Installing Rear Planetary Front
ThrustWasher
FRONT TABBED THRUST WASHER REAR PLANETARY GEAR
Fig. 184 Installing Spacer On Sun Gear
SUNGEAR SUN GEAR SPACER
Fig. 185 Installing Driving Shell Front ThrustPlate
On Sun Gear
SPACER SUN GEAR THRUST PLATE
Fig. 186 Installing Driving Shell Rear ThrustPlate
DRIVING SHELL SUNGEAR REAR THRUSTPLATE
ZG TRANSMISSION AND TRANSFER CASE 21 - 79
DISASSEMBLY AND ASSEMBLY (Continued)
(14) I nstal l front pl anetary gear on output shaft
and i n dri vi ng shel l (Fi g. 191).
(15) I nstal l front thrust washer on front pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace and be sure al l four washer tabs are seated.
(16) Assembl e front annul us gear and support, i f
necessary. Be sure support snap ri ng i s seated.
(17) I nstal l front annul us on front pl anetary (Fi g.
191).
(18) Posi ti on thrust pl ate on front annul us gear
support (Fi g. 192). Note that plate has two tabs
on it. These tabs fit in notches of annulus hub.
(19) I nstal l thrust washer i n front annul us (Fi g.
193). Align flat on washer with flat on planetary
hub. Also be sure washer tab is facing up.
(20) I nstal l front annul us snap ri ng (Fi g. 194). Use
snap ri ng pl i ers to avoi d di storti ng ri ng duri ng
i nstal l ati on. Al so be sure ri ng i s ful l y seated.
Fig. 187 Supporting Sun Gear On Wood Block
SUNGEAR DRIVING SHELL WOOD BLOCK
Fig. 188 Installing Sun Gear Lock Ring
LOCK RING GROOVE SUN GEAR LOCK RING DRIVING SHELL REAR THRUST PLATE
Fig. 189 Installing Assembled Sun Gear AndDriving
Shell On Output Shaft
SUN GEAR/DRIV- ING SHELL ASSEMBLY OUTPUTSHAFT
Fig. 190 Installing Rear Thrust Washer OnFront
Planetary Gear
FRONT PLAN- ETARY GEAR REAR TABBED THRUST WASHER
Fig. 191 Installing Front Planetary And
AnnulusGears
FRONT PLANETARY GEAR FRONT THRUST WASHER FRONT ANNU- LUS GEAR
21 - 80 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(21) I nstal l pl anetary sel ecti ve snap ri ng wi th
snap ri ng pl i ers (Fi g. 195). Be sure ri ng i s ful l y
seated.
(22) Turn pl anetary geartrai n assembl y over so
dri vi ng shel l i s faci ng workbench. Then support
geartrai n on wood bl ock posi ti oned under forward
end of output shaft. Thi s al l ows geartrai n compo-
nents to move forward for accurate end pl ay check.
(23) Check pl anetary geartrai n end pl ay wi th
feel er gauge (Fi g. 196). Gauge goes between shoul der
on output shaft and end of rear annul us support.
(24) Geartrai n end pl ay shoul d be 0.12 to 1.22 mm
(0.005 to 0.048 i n.). I f end pl ay i s i ncorrect, snap ri ng
(or thrust washers) may have to be repl aced. Snap
ri ng i s avai l abl e i n three di fferent thi cknesses for
adjustment purposes.
OVERDRIVE UNIT
DISASSEMBLY
(1) Remove transmi ssi on speed sensor and O-ri ng
seal from overdri ve case (Fi g. 197).
Fig. 192 Positioning Thrust Plate On FrontAnnulus
Support
FRONT ANNULUS THRUSTPLATE
Fig. 193 Installing Front Annulus Thrust Washer
WASHER FLAT ALIGNS WITH FLAT ON PLANE- TARY HUB FRONT ANNU- LUS THRUST WASHER TAB FACES FRONT
Fig. 194 Installing Front Annulus Snap Ring
SNAP RING PLIERS FRONT ANNU- LUS SNAP RING
Fig. 195 Installing Planetary Selective SnapRing
SELECTIVE SNAP RING SNAP RING PLIERS
Fig. 196 Checking Planetary Geartrain EndPlay
OUTPUT SHAFT REAR ANNU- LUS GEAR FEELER GAUGE
ZG TRANSMISSION AND TRANSFER CASE 21 - 81
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove overdri ve pi ston thrust beari ng (Fi g.
198).
OVERDRIVE PISTON DISASSEMBLY
(1) Remove overdri ve pi ston thrust pl ate (Fi g.
199). Retai n thrust pl ate. I t i s a sel ect fi t part and
may possi bl y be reused.
(2) Remove i ntermedi ate shaft spacer (Fi g. 200).
Retai n spacer. I t i s a sel ect fi t part and may possi bl y
be reused.
(3) Remove overdri ve pi ston from retai ner (Fi g.
201).
OVERDRIVE CLUTCH PACK DISASSEMBLY
(1) Remove overdri ve cl utch pack wi re retai ni ng
ri ng (Fi g. 202).
Fig. 197 Transmission Speed Sensor Removal/
Installation
SOCKET AND WRENCH SPEED SENSOR O-RING
Fig. 198 Overdrive Piston Thrust Bearing Removal/
Installation
THRUST BEAR- ING OVERDRIVE PISTON THRUST PLATE
Fig. 199 Overdrive Piston Thrust Plate Removal/
Installation
OVERDRIVE PISTON OVERDRIVE PISTON SPACER (SELECT FIT)
Fig. 200 Intermediate Shaft Spacer Location
INTERMEDIATESHAFT INTERMEDIATE SHAFT SPACER (SELECT FIT)
Fig. 201 Overdrive Piston Removal
PISTON RETAINER OVERDRIVE PISTON
21 - 82 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove overdri ve cl utch pack (Fi g. 203).
NOTE: The 42RE transmission has three clutch
discs and two clutch plates. The 44RE transmission
has four clutch discs and three clutch plates.
(3) Note posi ti on of cl utch pack components for
assembl y reference (Fi g. 204).
OVERDRIVE GEARTRAIN DISASSEMBLY
(1) Remove overdri ve cl utch wave spri ng (Fi g.
205).
Fig. 202 Removing Overdrive Clutch Pack
RetainingRing
OVERDRIVE CLUTCH PACK RETAININGRING
Fig. 203 Overdrive Clutch Pack Removal
OVERDRIVE CLUTCH PACK
Fig. 204 42RE Overdrive Clutch Component
Position
PRESSURE PLATE (TO FRONT) OVERDRIVE CLUTCH PACK CLUTCH DISC (3) CLUTCH PLATE (2) REACTION PLATE (TO REAR)
Fig. 205 Overdrive Clutch Wave Spring Removal/
Installation
WAVE SPRING
ZG TRANSMISSION AND TRANSFER CASE 21 - 83
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove overdri ve cl utch reacti on snap ri ng
(Fi g. 206). Note that snap ri ng i s l ocated i n same
groove as wave spri ng.
(3) Remove Torx head screws that attach access
cover and gasket to overdri ve case (Fi g. 207).
(4) Remove access cover and gasket (Fi g. 208).
(5) Expand output shaft beari ng snap ri ng wi th
expandi ng-type snap ri ng pl i ers. Then push output
shaft forward to rel ease shaft beari ng from l ocati ng
ri ng (Fi g. 209).
(6) Li ft gear case up and off geartrai n assembl y
(Fi g. 210).
(7) Remove snap ri ng that retai ns rear beari ng on
output shaft.
(8) Remove rear beari ng from output shaft (Fi g.
211).
Fig. 206 Overdrive Clutch Reaction Snap
RingRemoval/Installation
REACTION RING CLUTCH HUB
Fig. 207 Access Cover Screw Removal/Installation
TORX SCREWDRIVER (T25) ACCESS COVER SCREWS
Fig. 208 Access Cover And Gasket Removal/
Installation
ACCESS COVER AND GAS- KET
Fig. 209 Releasing Bearing From Locating Ring
EXPAND BEARING LOCAT- ING RING WITH SNAP RING PLIERS ACCESS HOLE PUSH OUTPUT SHAFT FOR- WARD TO FREE BEARING FROM RING
Fig. 210 Removing Gear Case From
GeartrainAssembly
GEARTRAIN ASSEMBLY GEAR CASE
Fig. 211 Rear Bearing Removal
OUTPUT SHAFT REAR BEARING SNAP RING
21 - 84 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
DIRECT CLUTCH, HUB AND SPRING DISASSEMBLY
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXI-
MATELY 830 POUNDS. USE SPRING COMPRESSOR
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES.
THE PRESS MUST ALSO HAVE A BED THAT CAN
BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrai n assembl y i n shop press (Fi g.
212).
(2) Posi ti on Compressor Tool 6227-1 on cl utch hub
(Fi g. 212). Support output shaft fl ange wi th steel
press pl ates as shown and center assembl y under
press ram.
(3) Appl y press pressure sl owl y. Compress hub and
spri ng far enough to expose cl utch hub retai ni ng ri ng
and rel i eve spri ng pressure on cl utch pack snap ri ng
(Fi g. 212).
(4) Remove di rect cl utch pack snap ri ng (Fi g. 213).
(5) Remove di rect cl utch hub retai ni ng ri ng (Fi g.
214).
(6) Rel ease press l oad sl owl y and compl etel y (Fi g.
215).
(7) Remove Speci al Tool 6227-1. Then remove
cl utch pack from hub (Fi g. 215).
Geartrain Disassembly
(1) Remove di rect cl utch hub and spri ng (Fi g. 216).
Fig. 212 Geartrain Mounted In Shop Press
PRESS RAM SPECIAL TOOL C-3995A (OR SIMILAR TOOL) CLUTCH HUB PLATES PRESS BED SPECIAL TOOL 62271
Fig. 213 Direct Clutch Pack Snap Ring Removal
CLUTCH HUB SPECIAL TOOL 62271 DIRECT CLUTCH PACK SNAP RING PRESS PLATES CLUTCH DRUM
Fig. 214 Direct Clutch Hub Retaining RingRemoval
SPECIAL TOOL 62271 CLUTCH HUB RETAININGRING PRESS BED PRESSPLATES
ZG TRANSMISSION AND TRANSFER CASE 21 - 85
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Remove sun gear and spri ng pl ate. Then
remove pl anetary thrust beari ng and pl anetary gear
(Fi g. 217).
(3) Remove overrunni ng cl utch assembl y wi th
expandi ng type snap ri ng pl i ers (Fi g. 218). I nsert pl i -
ers i nto cl utch hub. Expand pl i ers to gri p hub spl i nes
and remove cl utch wi th countercl ockwi se, twi sti ng
moti on.
(4) Remove thrust beari ng from overrunni ng
cl utch hub.
(5) Remove overrunni ng cl utch from hub.
(6) Mark posi ti on of annul us gear and di rect cl utch
drum for assembl y al i gnment reference (Fi g. 219).
Use smal l center punch or scri ber to make al i gnment
marks.
Fig. 215 Direct Clutch Pack Removal
SPECIAL TOOL 62271 DIRECT CLUTCH HUB DIRECT CLUTCH PACK
Fig. 216 Direct Clutch Hub And Spring Removal
DIRECT CLUTCHSPRING DIRECT CLUTCH HUB
Fig. 217 Removing Sun Gear, Thrust BearingAnd
Planetary Gear
PLANETARY GEAR PLANETARY THRUST BEARING CLUTCH SPRINGPLATE SPRING PLATE SNAP RING SUN GEAR
Fig. 218 Overrunning Clutch Assembly Removal/
Installation
OVERRUNNING CLUTCH NEEDLE BEARING
Fig. 219 Marking Direct Clutch Drum And
AnnulusGear For Assembly Alignment
DIRECT CLUTCH DRUM HAMMER PUNCH
21 - 86 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Remove di rect cl utch drum rear retai ni ng ri ng
(Fi g. 220).
(8) Remove di rect cl utch drum outer retai ni ng ri ng
(Fi g. 221).
(9) Mark annul us gear and output shaft for assem-
bl y al i gnment reference (Fi g. 222). Use punch or
scri ber to mark gear and shaft.
(10) Remove snap ri ng that secures annul us gear
on output shaft (Fi g. 223). Use two screwdri vers to
unseat and work snap ri ng out of groove as shown.
(11) Remove annul us gear from output shaft (Fi g.
224). Use rawhi de or pl asti c mal l et to tap gear off
shaft.
GEAR CASE AND PARK LOCK DISASSEMBLY
(1) Remove l ocati ng ri ng from gear case.
(2) Remove park pawl shaft retai ni ng bol t and
remove shaft, pawl and spri ng.
(3) Remove reacti on pl ug snap ri ng and remove
reacti on pl ug.
(4) Remove output shaft seal .
Fig. 220 Clutch Drum Inner Retaining RingRemoval
INNER RETAIN- ING RING DIRECT CLUTCH DRUM ANNULUS GEAR
Fig. 221 Clutch Drum Outer Retaining RingRemoval
OUTER RETAINING RING
Fig. 222 Marking Annulus Gear And Output ShaftFor
Assembly Alignment
OUTPUT SHAFT HAMMER PUNCH
Fig. 223 Annulus Gear Snap Ring Removal
OUTPUT SHAFT ANNULUS GEAR SNAP RING
Fig. 224 Annulus Gear Removal
OUTPUTSHAFT ANNULUS GEAR
ZG TRANSMISSION AND TRANSFER CASE 21 - 87
DISASSEMBLY AND ASSEMBLY (Continued)
OVERDRIVE UNIT ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH ASSEMBLY
(1) Soak di rect cl utch and overdri ve cl utch di scs i n
Mopar ATF Pl us transmi ssi on fl ui d. Al l ow di scs to
soak for 10-20 mi nutes.
(2) I nstal l new pi l ot bushi ng and cl utch hub bush-
i ng i n output shaft i f necessary (Fi g. 225). Lubri cate
bushi ngs wi th petrol eum jel l y, or transmi ssi on fl ui d.
(3) I nstal l annul us gear on output shaft, i f
removed. Then i nstal l annul us gear retai ni ng snap
ri ng (Fi g. 226).
(4) Al i gn and i nstal l cl utch drum on annul us gear
(Fi g. 227). Be sure drum i s engaged i n annul us gear
l ugs.
(5) I nstal l cl utch drum outer retai ni ng ri ng (Fi g.
227).
(6) Sl i de cl utch drum forward and i nstal l i nner
retai ni ng ri ng (Fi g. 228).
(7) I nstal l rear beari ng and snap ri ng on output
shaft (Fi g. 229). Be sure l ocati ng ri ng groove i n bear-
i ng i s toward rear.
(8) I nstal l overrunni ng cl utch on hub (Fi g. 230).
Note that clutch only fits one way. Shoulder on
clutch should seat in small recess at edge of
hub.
(9) I nstal l thrust beari ng on overrunni ng cl utch
hub. Use generous amount of petrol eum jel l y to hol d
beari ng i n pl ace for i nstal l ati on. Bearing fits one
Fig. 225 Output Shaft Pilot Bushing
OUTPUT SHAFT HUB OVERRUNNING CLUTCH HUB BUSH- ING INTERMEDIATE SHAFT PILOT BUSH- ING
Fig. 226 Annulus Gear Installation
SNAPRINGOUTPUT SHAFT FRONT BEARING ANNULUSGEAR
Fig. 227 Clutch Drum And Outer Retaining
RingInstallation
ANNULUSGEAR OUTER SNAPRING CLUTCH DRUM
Fig. 228 Clutch Drum Inner Retaining
RingInstallation
ANNULUS GEAR INNER SNAP RING CLUTCH DRUM
Fig. 229 Rear Bearing And Snap Ring Installation
REAR BEARING SNAP RING
21 - 88 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
way only. Be sure bearing is seated squarely
against hub. Reinstall bearing if it does not
seat squarely.
(10) I nstal l overrunni ng cl utch i n output shaft
(Fi g. 231). I nsert snap ri ng pl i ers i n hub spl i nes.
Expand pl i ers to gri p hub. Then i nstal l assembl y
wi th countercl ockwi se, twi sti ng moti on.
(11) I nstal l pl anetary gear i n annul us gear (Fi g.
232). Be sure planetary pinions are fully seated
in annulus gear before proceeding.
(12) Coat pl anetary thrust beari ng and beari ng
contact surface of spri ng pl ate wi th generous amount
of petrol eum jel l y. Thi s wi l l hel p hol d beari ng i n
pl ace duri ng i nstal l ati on.
(13) I nstal l pl anetary thrust beari ng on sun gear
(Fi g. 233). Sl i de beari ng onto gear and seat i t agai nst
spri ng pl ate as shown. Bearing fits one way only.
If it does not seat squarely against spring plate,
remove and reposition bearing.
Fig. 230 Assembling Overrunning Clutch AndHub
CLUTCH HUB OVERRUNNING CLUTCH
Fig. 231 Overrunning Clutch Installation
CLUTCH DRUM OVERRUNNING CLUTCH ASSEMBLY EXPANDING-TYPE SNAP RING PLI- ERS CLUTCH DRUM ANNULUSGEAR OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT SHAFT
Fig. 232 Planetary Gear Installation
PLANETARY GEAR ANNULUS GEAR
Fig. 233 Planetary Thrust Bearing Installation
SPRING PLATE PLANETARY THRUST BEARING SUNGEAR
ZG TRANSMISSION AND TRANSFER CASE 21 - 89
DISASSEMBLY AND ASSEMBLY (Continued)
(14) I nstal l assembl ed sun gear, spri ng pl ate and
thrust beari ng (Fi g. 234). Be sure sun gear and
thrust beari ng are ful l y seated before proceedi ng.
(15) Mount assembl ed output shaft, annul us gear,
and cl utch drum i n shop press. Di rect cl utch spri ng,
hub and cl utch pack are easi er to i nstal l wi th assem-
bl y mounted i n press.
(16) Al i gn spl i nes i n hubs of pl anetary gear and
overrunni ng cl utch wi th Al i gnment tool 6227-2 (Fi g.
235). I nsert tool through sun gear and i nto spl i nes of
both hubs. Be sure al i gnment tool i s ful l y seated
before proceedi ng.
(17) I nstal l di rect cl utch spri ng (Fi g. 236). Be sure
spri ng i s properl y seated on spri ng pl ate.
NOTE: The 42RE transmission has 6 direct clutch
discs and 5 clutch plates. The 44RE transmission
has 8 direct clutch discs and 7 clutch plates.
(18) Assembl e and i nstal l di rect cl utch pack on
hub as fol l ows:
(a) Assembl e cl utch pack components (Fi g. 237)
or (Fi g. 238).
(b) I nstal l di rect cl utch reacti on pl ate on cl utch
hub fi rst. Note that one side of reaction plate
is counterbored. Be sure this side faces rear-
ward. Splines at rear of hub are raised
slightly. Counterbore in plate fits over raised
splines. Plate should be flush with this end of
hub (Fig. 239).
(c) I nstal l fi rst cl utch di sc fol l owed by a steel
pl ate unti l al l di scs and pl ates have been i nstal l ed.
(d) I nstal l pressure pl ate. Thi s i s l ast cl utch
pack i tem to be i nstal l ed. Be sure plate is
installed with shoulder side facing upward
(Fig. 240).
(19) I nstal l cl utch hub and cl utch pack on di rect
cl utch spri ng (Fi g. 241). Be sure hub is started on
sun gear splines before proceeding.
Fig. 234 Sun Gear Installation
SUN GEAR AND SPRING PLATE ASSEMBLY
Fig. 235 Alignment Tool Installation
SPECIAL TOOL 62272 PRESSPLATES ASSEMBLED DRUM AND ANNULUS GEAR SUN GEAR
Fig. 236 Direct Clutch Spring Installation
SPECIAL TOOL 62272 DIRECT CLUTCH SPRING CLUTCH HUB PRESS PLATES
21 - 90 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
WARNING: THE NEXT STEP IN GEARTRAIN
ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 830 POUNDS. USE COMPRES-
SOR TOOL C-6227-1 AND A HYDRAULIC-TYPE
SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6
INCHES. THE PRESS MUST ALSO HAVE A BED
THAT CAN BE ADJUSTED UP OR DOWN AS
REQUIRED. RELEASE CLUTCH SPRING TENSION
SLOWLY AND COMPLETELY TO AVOID PERSONAL
INJURY.
(20) Posi ti on Compressor Tool 6227-1 on cl utch
hub.
(21) Compress cl utch hub and spri ng just enough
to pl ace tensi on on hub and hol d i t i n pl ace.
(22) Sl owl y compress cl utch hub and spri ng. Com-
press spri ng and hub onl y enough to expose ri ng
grooves for cl utch pack snap ri ng and cl utch hub
retai ni ng ri ng.
(23) Real i gn cl utch pack on hub and seat cl utch
di scs and pl ates i n cl utch drum.
(24) I nstal l di rect cl utch pack snap ri ng (Fi g. 242).
Be very sure snap ring is fully seated in clutch
drum ring groove.
(25) I nstal l cl utch hub retai ni ng ri ng (Fi g. 243).
Be very sure retaining ring is fully seated in
sun gear ring groove.
Fig. 237 42RE Direct Clutch Pack Components
REACTION PLATE DIRECT CLUTCH DISCS (6) PRESSUREPLATE CLUTCH PLATES (5)
Fig. 238 44RE Direct Clutch Pack Components
CLUTCH DISCS (8) PRESSURE PLATE CLUTCH PLATES (7) REACTIONPLATE
ZG TRANSMISSION AND TRANSFER CASE 21 - 91
DISASSEMBLY AND ASSEMBLY (Continued)
(26) Sl owl y rel ease press ram, remove compressor
tool s and remove geartrai n assembl y.
Fig. 239 Correct Position Of Direct ClutchReaction
Plate
REACTION PLATE COUN- TERBORE DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF HUB) CLUTCHHUB
Fig. 240 Correct Position Of Direct ClutchPressure
Plate
DIRECT CLUTCH PRES- SURE PLATE CLUTCH PACK BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
Fig. 241 Direct Clutch Pack And Clutch
HubInstallation
CLUTCH HUB DIRECT CLUTCH PACK CLUTCH DRUM
Fig. 242 Direct Clutch Pack Snap Ring Installation
SPECIAL TOOL 62271 DIRECT CLUTCH PACK SNAP RING
Fig. 243 Clutch Hub Retaining Ring Installation
SPECIAL TOOL62271 CLUTCH HUB RETAINING RING
21 - 92 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
GEAR CASE ASSEMBLY
(1) Posi ti on park pawl and spri ng i n case and
i nstal l park pawl shaft. Veri fy that end of spri ng
wi th 90 bend i s hooked to pawl and strai ght end of
spri ng i s seated agai nst case.
(2) I nstal l pawl shaft retai ni ng bol t. Ti ghten bol t
to 27 Nm (20 ft. l bs.) torque.
(3) I nstal l park l ock reacti on pl ug. Note that plug
has locating pin at rear (Fig. 244). Be sure pin
is seated in hole in case before installing snap
ring.
(4) I nstal l reacti on pl ug snap-ri ng (Fi g. 245). Com-
press snap ring only enough for installation; do
not distort it.
(5) I nstal l new seal i n gear case. On 4x4 gear case,
use Tool Handl e C-4171 and I nstal l er C-3860-A to
seat seal i n case. On 4 x 2 gear case, use same Han-
dl e C-4171 and I nstal l er C-3995-A to seat seal i n
case.
(6) Veri fy that tab ends of rear beari ng l ocati ng
ri ng extend i nto access hol e i n gear case (Fi g. 246).
(7) Support geartrai n on Tool 6227-1 (Fi g. 247). Be
sure tool i s securel y seated i n cl utch hub.
(8) I nstal l overdri ve gear case on geartrai n (Fi g.
247).
(9) Expand front beari ng l ocati ng ri ng wi th snap
ri ng pl i ers (Fi g. 248). Then sl i de case downward unti l
l ocati ng ri ng l ocks i n beari ng groove and rel ease
snap ri ng.
(10) I nstal l l ocati ng ri ng access cover and gasket
i n overdri ve uni t case (Fi g. 249).
Fig. 244 Reaction Plug Locating Pin And Snap-Ring
REACTION PLUG SNAP RING (DO NOT OVERCOM- PRESS TO INSTALL) LOCATING PIN PARK LOCK REACTIONPLUG
Fig. 245 Reaction Plug And Snap-Ring Installation
REACTION PLUG SNAP RING SNAP RING PLI- ERS
Fig. 246 Correct Rear Bearing Locating RingPosition
CASE ACCESS HOLE TAB ENDS OF LOCATING RING
Fig. 247 Overdrive Gear Case Installation
GEARTRAIN ASSEMBLY GEAR CASE
Fig. 248 Seating Locating Ring In Rear Bearing
EXPAND BEARING LOCAT- ING RING WITH SNAP RING PLIERS ACCESS HOLE PUSH OUTPUT SHAFT FOR- WARD TO FREE BEARING FROM RING
ZG TRANSMISSION AND TRANSFER CASE 21 - 93
DISASSEMBLY AND ASSEMBLY (Continued)
OVERDRIVE CLUTCH ASSEMBLY
(1) I nstal l overdri ve cl utch reacti on ri ng fi rst.
Reacti on ri ng i s fl at wi th notched ends (Fi g. 250).
(2) I nstal l wave spri ng on top of reacti on ri ng (Fi g.
251). Reaction ring and wave ring both fit in
same ring groove. Use screwdri ver to seat each
ri ng securel y i n groove. Al so ensure that the ends of
the two ri ngs are offset from each other.
NOTE: The 42RE transmission has 3 overdrive
clutch discs and 2 plates. The 44RE transmission
has 4 overdrive clutch discs and 3 plates
(3) Assembl e overdri ve cl utch pack (Fi g. 252).
(4) I nstal l overdri ve cl utch reacti on pl ate fi rst.
(5) I nstal l fi rst cl utch di sc fol l owed by fi rst cl utch
pl ate. Then i nstal l remai ni ng cl utch di scs and pl ates
i n same order.
(6) I nstal l cl utch pack pressure pl ate.
(7) I nstal l cl utch pack wi re-type retai ni ng ri ng
(Fi g. 253).
INTERMEDIATE SHAFT SPACER SELECTION
(1) Pl ace overdri ve uni t i n verti cal posi ti on. Mount
i t on bl ocks, or i n workbench wi th appropri ate si ze
mounti ng hol e cut i nto i t. Be sure uni t i s faci ng
upward for access to di rect cl utch hub. Al so be sure
Fig. 252 42RE Overdrive Clutch Components
REACTIONPLATE OVERDRIVE CLUTCH DISCS (3) PRESSUREPLATE CLUTCH PLATES (2)
Fig. 249 Locating Ring Access Cover And
GasketInstallation
TORX SCREWDRIVER (T25) ACCESS COVER SCREWS
Fig. 250 Overdrive Clutch Reaction Ring Installation
REACTION RING CLUTCH HUB
Fig. 251 Overdrive Clutch Wave Spring Installation
WAVE SPRING
21 - 94 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
output shaft i s not l oaded and i nternal components
are moved rearward for accurate measurement.
(2) Determi ne correct thi ckness i ntermedi ate shaft
spacer as fol l ows:
(a) I nsert Speci al Tool 6312 through sun gear,
pl anetary gear and i nto pi l ot bushi ng i n output
shaft. Be sure tool bottoms agai nst pl anetary
shoul der.
(b) Posi ti on Gauge Tool 6311 across face of over-
dri ve case (Fi g. 254). Then posi ti on Di al Cal i per
C-4962 over gauge tool .
(c) Extend sl i di ng scal e of di al cal i per downward
through gauge tool sl ot unti l scal e contacts end of
Gauge Al i gnment Tool 6312. Lock scal e i n pl ace.
Remove di al cal i per tool and note di stance mea-
sured (Fi g. 254).
(d) Sel ect proper thi ckness end pl ay spacer from
spacer chart based on di stance measured (Fi g.
255).
(e) Remove Gauge Al i gnment Tool 6312.
OD THRUST PLATE SELECTION
(1) Pl ace overdri ve uni t i n verti cal posi ti on. Mount
i t on bl ocks, or i n workbench wi th appropri ate si ze
mounti ng hol e cut i nto i t. Be sure uni t i s faci ng
upward for access to di rect cl utch hub. Al so be sure
output shaft i s not l oaded and i nternal components
are moved rearward for accurate measurement.
(2) Determi ne correct thi ckness overdri ve pi ston
thrust pl ate as fol l ows:
(a) Posi ti on Gauge Tool 6311 across face of over-
dri ve case. Then posi ti on Di al Cal i per C-4962 over
gauge tool (Fi g. 256).
(b) Measure di stance to cl utch hub thrust bear-
i ng seat at four poi nts 90 apart. Then average
measurements by addi ng them and di vi di ng by 4.
(c) Sel ect and i nstal l requi red thrust pl ate from
i nformati on i n thrust pl ate chart (Fi g. 257).
(3) Leave Al i gnment Tool 6227-2 i n pl ace. Tool wi l l
keep pl anetary and cl utch hub spl i nes i n al i gnment
unti l overdri ve uni t i s ready for i nstal l ati on on trans-
mi ssi on.
(4) Transmi ssi on speed sensor can be i nstal l ed at
thi s ti me i f desi red. However, i t i s recommended that
sensor not be i nstal l ed unti l after overdri ve uni t i s
secured to transmi ssi on.
Fig. 253 Overdrive Clutch Pack Retaining
RingInstallation
OVERDRIVE CLUTCH PACK RETAININGRING
Fig. 254 Shaft End Play Measurement
SPECIAL TOOL 6312 SPECIAL TOOL 6311 SPECIAL TOOL C-4962
Fig. 255 Intermediate Shaft End Play
SpacerSelection
End Play Measurement (Inches) Spacer Thickness (Inches)
Fig. 256 Overdrive Piston Thrust Plate Measurement
SPECIAL TOOL 6311 DIRECT CLUTCH HUB THRUST BEARING SEAT SPECIAL TOOL C-4962
ZG TRANSMISSION AND TRANSFER CASE 21 - 95
DISASSEMBLY AND ASSEMBLY (Continued)
OVERDRIVE PISTON ASSEMBLY
(1) I nstal l new seal s on over dri ve pi ston.
(2) Stand transmi ssi on case upri ght on bel l hous-
i ng.
(3) Posi ti on Gui de Ri ng 8114-1 on outer edge of
overdri ve pi ston retai ner.
(4) Posi ti on Seal Gui de 8114-2 on i nner edge of
overdri ve pi ston retai ner.
(5) I nstal l overdri ve pi ston i n overdri ve pi ston
retai ner by: al i gni ng l ocati ng l ugs on overdri ve pi ston
to the two mati ng hol es i n retai ner.
(a) Al i gni ng l ocati ng l ugs on overdri ve pi ston to
the two mati ng hol es i n retai ner.
(b) Lubri cate overdri ve pi ston seal s wi th Mopar
Door Ease, or equi val ent.
(c) I nstal l pi ston over Seal Gui de 81142 and
i nsi de Gui de Ri ng 81141.
(d) Push overdri ve pi ston i nto posi ti on i n
retai ner.
(e) Veri fy that the l ocati ng l ugs entered the l ug
bores i n the retai ner.
(6) I nstal l i ntermedi ate shaft spacer on i ntermedi -
ate shaft.
(7) I nstal l overdri ve pi ston thrust pl ate on over-
dri ve pi ston.
(8) I nstal l overdri ve pi ston thrust beari ng on over-
dri ve pi ston.
(9) I nstal l transmi ssi on speed sensor and O-ri ng
seal i n overdri ve case (Fi g. 197).
CLEANING AND INSPECTION
VALVE BODY
Cl ean the val ve housi ngs, val ves, pl ugs, spri ngs,
and separator pl ates wi th a standard parts cl eani ng
sol uti on onl y. Do not use gasol i ne, kerosene, or any
type of causti c sol uti on.
Do not i mmerse any of the el ectri cal components i n
cl eani ng sol uti on. Cl ean the governor sol enoi d and
sensor and the dual sol enoi d and harness assembl y
by wi pi ng them off wi th dry shop towel s onl y.
Dry al l except the el ectri cal parts wi th compressed
ai r. Make sure al l passages are cl ean and free from
obstructi ons. Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Wi pe the governor pressure sensor and sol enoi d
val ve wi th dry, l i nt free shop towel s onl y. The O-ri ngs
on the sensor and sol enoi d val ve are the onl y servi ce-
abl e components. Be sure the vent ports i n the sol e-
noi d val ve are open and not bl ocked by di rt or debri s.
Repl ace the val ve and/or sensor onl y when DRB scan
tool di agnosi s i ndi cates thi s i s necessary. Or, i f ei ther
part has sustai ned physi cal damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end
of the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
I nspect the throttl e and manual val ve l evers and
shafts (Fi g. 258). Do not attempt to strai ghten a bent
shaft or correct a l oose l ever. Repl ace these compo-
nents i f worn, bent, l oose or damaged i n any way.
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th a
sheet of crocus cl oth. Posi ti on the crocus cl oth on a
surface pl ate, sheet of pl ate gl ass or equal l y fl at sur-
face. I f di storti on i s severe or any surfaces are
heavi l y scored, the val ve body wi l l have to be
repl aced.
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the
dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
Fig. 257 Overdrive Piston Thrust Plate Selection
End Play Measurement (Inches) Spacer Thickness (Inches)
21 - 96 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Mi nor surface scratches on steel
val ves and pl ugs can be removed wi th crocus cl oth
but do not round off the edges of the valve or
plug lands. Mai ntai ni ng sharpness of these edges i s
vi tal l y i mportant. The edges prevent forei gn matter
from l odgi ng between the val ves and pl ugs and the
bore.
I nspect al l the val ve and pl ug bores i n the val ve
body. Use a penl i ght to vi ew the bore i nteri ors.
Repl ace the val ve body i f any bores are di storted or
scored. I nspect al l of the val ve body spri ngs. The
spri ngs must be free of di storti on, warpage or broken
coi l s.
Check the two separator pl ates for di storti on or
damage of any ki nd. I nspect the upper housi ng,
l ower housi ng, 3-4 accumul ator housi ng, and transfer
pl ate careful l y. Be sure al l fl ui d passages are cl ean
and cl ear. Check condi ti on of the upper housi ng and
transfer pl ate check bal l s as wel l . The check bal l s
and bal l seats must not be worn or damaged.
Tri al fi t each val ve and pl ug i n i ts bore to check
freedom of operati on. When cl ean and dry, the val ves
and pl ugs shoul d drop freel y i nto the bores.
Val ve body bores do not change di mensi onal l y wi th
use. I f the val ve body functi oned correctl y when new,
i t wi l l conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
The onl y servi ceabl e val ve body components are
l i sted bel ow. The remai ni ng val ve body components
are servi ced onl y as part of a compl ete val ve body
assembl y. Servi ceabl e parts are:
dual sol enoi d and harness assembl y
sol enoi d gasket
sol enoi d case connector O-ri ngs and shoul der
bol t
swi tch val ve and spri ng
pressure adjusti ng screw and bracket assembl y
throttl e l ever
manual l ever and shaft seal
throttl e l ever shaft seal , washer, and E-cl i p
fl ui d fi l ter and screws
detent bal l and spri ng
val ve body screws
governor pressure sol enoi d
governor pressure sensor and retai ni ng cl i p
park l ock rod and E-cl i p
ZG TRANSMISSION AND TRANSFER CASE 21 - 97
CLEANING AND INSPECTION (Continued)
F
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21 - 98 TRANSMISSION AND TRANSFER CASE ZG
CLEANING AND INSPECTION (Continued)
TRANSMISSION
GENERAL INFORMATION
I nspect the transmi ssi on bushi ngs duri ng overhaul .
Bushi ng condi ti on i s i mportant as worn, scored bush-
i ngs contri bute to l ow pressures, cl utch sl i p and
accel erated wear of other components. However, do
not repl ace bushi ngs as a matter of course. Repl ace
bushi ngs onl y when they are actual l y worn, or
scored.
Use recommended tool s to repl ace bushi ngs. The
tool s are si zed and desi gned to remove, i nstal l , and
seat bushi ngs correctl y. The bushi ng repl acement
tool s are i ncl uded i n Bushi ng Tool Set C-3887-B.
Pre-si zed servi ce bushi ngs are avai l abl e for
repl acement purposes. Onl y the sun gear bushi ngs
are not servi ced. Low cost of the sun gear assembl y
makes i t easi er to si mpl y repl ace the gear and bush-
i ngs as an assembl y.
Hel i -Coi l i nserts can be used to repai r damaged,
stri pped or worn threads i n al umi num parts. These
i nserts are avai l abl e from most automoti ve parts
suppl i ers. Stai nl ess steel i nserts are recommended.
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on
shafts, or val ves, use extreme care to avoi d roundi ng
off sharp edges. Sharp edges are vi tal as they pre-
vent forei gn matter from getti ng between the val ve
and val ve bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or
O-ri ngs duri ng overhaul . Repl ace these parts as a
matter of course. Al so do not reuse snap ri ngs or
E-cl i ps that are bent or di storted. Repl ace these parts
as wel l .
Lubri cate transmi ssi on parts wi th Mopar ATF
Pl us, Type 7176, transmi ssi on fl ui d duri ng overhaul
and assembl y. Use petrol eum jel l y, Mopar Door
Ease, or Ru-Gl yde to prel ubri cate seal s, O-ri ngs, and
thrust washers. Petrol eum jel l y can al so be used to
hol d parts i n pl ace duri ng reassembl y.
TRANSMISSION CASE CLEANING AND
INSPECTION
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
I nspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repai red wi th Hel i coi l thread i nserts. However, the
case wi l l have to be repl aced i f i t exhi bi ts any type of
damage or wear.
Lubri cate the front band adjusti ng screw threads
wi th petrol eum jel l y and thread the screw part-way
i nto the case. Be sure the screw turns freel y.
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM/OVERDRIVE PISTON RETAINER
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
l ow-reverse drum, and overdri ve pi ston retai ner i n
sol vent. Dry them wi th compressed ai r after cl ean-
i ng.
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse drum i f the cl utch race,
rol l er surface or i nsi de di ameter i s scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Exami ne the overdri ve pi ston retai ner careful l y for
wear, cracks, scori ng or other damage. Be sure the
retai ner hub i s a snug fi t i n the case and drum.
Repl ace the retai ner i f worn or damaged.
ACCUMULATOR
I nspect the accumul ator pi ston and seal ri ngs (Fi g.
259). Repl ace the seal ri ngs i f worn or cut. Repl ace
the pi ston i f chi pped or cracked.
Check condi ti on of the accumul ator i nner and
outer spri ngs (Fi g. 259). Repl ace the spri ngs i f the
coi l s are cracked, di storted or col l apsed.
FRONT SERVO
Cl ean the servo pi ston components wi th sol vent
and dry them wi th compressed ai r. Wi pe the band
cl ean wi th l i nt free shop towel s.
Fig. 259 Accumulator Components
INNERSPRING ACCUMULATOR PIS- TON OUTERSPRING SEAL RINGS
ZG TRANSMISSION AND TRANSFER CASE 21 - 99
CLEANING AND INSPECTION (Continued)
Repl ace the front band i f di storted, l i ni ng i s
burned, fl aki ng off, or worn to the poi nt where the
grooves i n the l i ni ng materi al are no l onger vi si bl e.
I nspect the servo components. Repl ace the spri ngs
i f col l apsed, di storted or broken. Repl ace the gui de,
rod and pi ston i f cracked, bent, or worn. Di scard the
servo snap ri ng i f di storted or warped.
Check the servo pi ston bore for wear. I f the bore i s
severel y scored, or damaged, i t wi l l be necessary to
repl ace the case.
Repl ace any servo component i f doubt exi sts about
condi ti on. Do not reuse suspect parts.
REAR SERVO
Remove and di scard the servo pi ston seal ri ng (Fi g.
260). Then cl ean the servo components wi th sol vent
and dry wi th compressed ai r. Repl ace ei ther spri ng i f
col l apsed, di storted or broken. Repl ace the pl ug and
pi ston i f cracked, bent, or worn. Di scard the servo
snap ri ngs and use a new ones at assembl y.
FRONT CLUTCH
Cl ean the front cl utch components i n sol vent and
dry them wi th compressed ai r onl y. Do not use rags
or shop towel s to dry any of the cl utch parts. Li nt
from such materi al s wi l l adhere to the component
surfaces and coul d restri ct or bl ock fl ui d passages
after assembl y.
Repl ace the cl utch di scs i f warped, worn, scored,
burned or charred, or i f the faci ng i s fl aki ng off.
Repl ace the steel pl ates i f heavi l y scored, warped, or
broken. Be sure the dri vi ng l ugs on the pl ates are i n
good condi ti on. The l ugs must not be bent, cracked or
damaged i n any way.
Repl ace the cl utch spri ng and spri ng retai ner i f
ei ther i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged.
Check acti on of the check bal l i n the retai ner (Fi g.
261). The bal l must move freel y and not sti ck.
NOTE: Inspect the clutch retainer bushings care-
fully (Fig. 262). The retainer bushings are NOT ser-
viceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
REAR CLUTCH
Cl ean the cl utch components wi th sol vent and dry
them wi th compressed ai r. Do not use rags or shop
towel s to dry any of the cl utch parts. Li nt from such
materi al s wi l l adhere to component surfaces and
coul d restri ct or bl ock fl ui d passages after assembl y.
Repl ace the cl utch di scs i f warped, worn, scored,
burned/charred, the l ugs are damaged, or i f the fac-
i ng i s fl aki ng off. Repl ace the top and bottom pres-
sure pl ates i f scored, warped, or cracked. Be sure the
dri vi ng l ugs on the pressure and cl utch pl ates are
al so i n good condi ti on. The l ugs must not be bent,
cracked or damaged i n any way.
Fig. 260 Rear Servo Components
SNAPRING PISTON SEAL PISTON PLUG SPRING RETAINER SNAPRING PISTON SPRING CUSHIONSPRING PISTON
Fig. 261 Front Clutch Piston Retainer CheckBall
Location
RETAINER CHECK BALL
Fig. 262 Retainer Bushing Location/Inspection
FRONT CLUTCH RETAINER BUSHINGS (NON-SERVICE- ABLE)
21 - 100 TRANSMISSION AND TRANSFER CASE ZG
CLEANING AND INSPECTION (Continued)
Repl ace the pi ston spri ng and wave spri ng i f ei ther
part i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
cl utch and pressure pl ates shoul d sl i de freel y i n the
sl ots. Repl ace the retai ner i f the grooves are worn or
damaged. Al so check acti on of the check bal l s i n the
retai ner and pi ston. Each check bal l must move
freel y and not sti ck.
Repl ace the retai ner bushi ng i f worn, scored, or
doubt exi sts about bushi ng condi ti on.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
Check condi ti on of the fi ber thrust washer and
metal output shaft thrust washer. Repl ace ei ther
washer i f worn or damaged.
Check condi ti on of the seal ri ngs on the i nput shaft
and cl utch retai ner hub. Repl ace the seal ri ngs onl y
i f worn, di storted, or damaged. The i nput shaft front
seal ri ng i s tefl on wi th chamfered ends. The rear ri ng
i s metal wi th i nterl ocki ng ends.
Check the i nput shaft for wear, or damage. Repl ace
the shaft i f worn, scored or damaged i n any way.
PLANETARY GEARTRAIN
Cl ean the pl anetary components i n sol vent and dry
them wi th compressed ai r.
Check sun gear and dri vi ng shel l condi ti on.
Repl ace the gear i f damaged or i f the bushi ngs are
scored or worn. The bushi ngs are not servi ceabl e.
Repl ace the dri vi ng shel l i f worn, cracked or dam-
aged.
Repl ace pl anetary gear sets i f gears, pi ni on pi ns, or
carri er are damaged i n any way. Repl ace the annul us
gears and supports i f ei ther component i s worn or
damaged.
I nspect the geartrai n spacers, thrust pl ates, snap
ri ngs, and thrust washers. Repl ace any of these parts
that are worn, di storted or damaged. Do not attempt
to reuse these parts.
The pl anetary gear thrust washers are di fferent
si zes. The l arge di ameter washers go on the front
pl anetary and the smal l er washers go on the rear
pl anetary. Al l the washers have four l ocati ng tabs on
them. These tabs fi t i n the hol es or sl ots provi ded i n
each pl anetary gear.
I nspect the output shaft careful l y. Pay parti cul ar
attenti on to the machi ned bushi ng/beari ng surfaces
on the shaft and the governor val ve shaft bore at the
shaft rear.
Repl ace the output shaft i f the machi ned surfaces
are scored, pi tted, or damaged i n any way. Al so
repl ace the shaft i f the spl i nes are damaged, or
exhi bi ts cracks at any l ocati on (especi al l y at the gov-
ernor val ve shaft bore).
The annul us gears can be removed from thei r sup-
ports i f necessary. Just remove the snap ri ngs and
separate the two parts when repl acement i s neces-
sary. I n addi ti on, the annul us gear bushi ngs can be
repl aced i f severel y worn, or scored. However i t i s not
necessary to repl ace the bushi ngs i f they onl y exhi bi t
normal wear. Check bushi ng fi t on the output shaft
to be sure.
OVERDRIVE UNIT
Cl ean the geartrai n and case components wi th sol -
vent. Dry al l parts except the beari ngs wi th com-
pressed ai r. Al l ow beari ngs to ai r dry.
Do not use shop towel s for wi pi ng parts dry unl ess
the towel s are made from a l i nt-free materi al . A suf-
fi ci ent quanti ty of l i nt (from shop towel s, cl oths, rags,
etc.) coul d pl ug the transmi ssi on fi l ter and fl ui d pas-
sages.
Di scard the ol d case gasket and seal s. Do not
attempt to sal vage these parts. They are not reus-
abl e. Repl ace any of the overdri ve uni t snap ri ngs i f
di storted or damaged.
Mi nor ni cks or scratches on components can be
smoothed wi th crocus cl oth. However, do not attempt
to reduce severe scori ng on any components wi th
abrasi ve materi al s. Repl ace severel y scored compo-
nents; do not try to sal vage them.
Check condi ti on of the park l ock components and
the overdri ve case.
Repl ace the case i f cracked, scored, or damaged.
Repl ace the park l ock pawl , pl ug, or spri ng i f worn or
damaged. Be sure the bul l et at the end of the park
l ock rod i s i n good condi ti on. Repl ace the rod i f the
bul l et i s worn or the rod i tsel f i s bent or di storted.
Do not attempt to strai ghten the rod.
Check the bushi ngs i n the overdri ve case. Repl ace
the bushi ngs i f severel y scored or worn. Al so repl ace
the case seal i f l oose, di storted, or damaged.
Exami ne the overdri ve and di rect cl utch di scs and
pl ates. Repl ace the di scs i f the faci ng i s worn,
severel y scored, or burned and fl aki ng off. Repl ace
the cl utch pl ates i f worn, heavi l y scored, or cracked.
Check the l ugs on the cl utch pl ates for wear. The
pl ates shoul d sl i de freel y i n the drum. Repl ace the
pl ates or drum i f bi ndi ng occurs.
Check condi ti on of the annul us gear, di rect cl utch
hub, cl utch drum and cl utch spri ng. Repl ace the gear,
hub and drum i f worn or damaged. Repl ace the
spri ng i f col l apsed, di storted, or cracked.
Be sure the spl i nes and l ugs on the gear, drum and
hub are i n good condi ti on. The cl utch pl ates and
di scs shoul d sl i de freel y i n these components.
I nspect the thrust beari ngs and spri ng pl ate.
Repl ace the pl ate i f worn or scored. Repl ace the bear-
i ngs i f rough, noi sy, bri nnel l ed, or worn.
ZG TRANSMISSION AND TRANSFER CASE 21 - 101
CLEANING AND INSPECTION (Continued)
I nspect the pl anetary gear assembl y and the sun
gear and bushi ngs. I f ei ther the sun gear or the
bushi ngs are damaged, repl ace the gear and bush-
i ngs as an assembl y. The gear and bushi ngs are not
servi ced separatel y.
The pl anetary carri er and pi ni ons must be i n good
condi ti on. Al so be sure the pi ni on pi ns are secure and
i n good condi ti on. Repl ace the carri er i f worn or dam-
aged.
I nspect the overrunni ng cl utch and race. The race
surface shoul d be smooth and free of scores. Repl ace
the overrunni ng cl utch assembl y or the race i f ei ther
assembl y i s worn or damaged i n any way.
I nspect the output shaft and governor components.
Repl ace the shaft pi l ot bushi ng and i nner bushi ng i f
damaged. Repl ace ei ther shaft beari ng i f rough or
noi sy. Repl ace the beari ng snap ri ngs i f di storted or
cracked.
Check the machi ned surfaces on the output shaft.
These surfaces shoul d cl ean and smooth. Very mi nor
ni cks or scratches can be smoothed wi th crocus cl oth.
Repl ace the shaft i f worn, scored or damaged i n any
way.
I nspect the output shaft bushi ngs. The smal l bushi ng i s
the i ntermedi ate shaft pi l ot bushi ng. The l arge bushi ng i s
the overrunni ng cl utch hub bushi ng. Repl ace ei ther bush-
i ng i f scored, pi tted, cracked, or worn.
ADJ USTMENTS
BRAKE TRANSMISSION SHIFT INTERLOCK
The park i nterl ock cabl e i s part of the brake/shi ft
l ever i nterl ock system. Correct cabl e adjustment i s
i mportant to proper i nterl ock operati on. The gear
shi ft and park l ock cabl es must both be correctl y
adjusted i n order to shi ft out of Park.
Park Interloc k Cable Adjustment Proc edure
(1) Shi ft i nto Park posi ti on.
(2) Turn i gni ti on swi tch to Accessory posi ti on. Be
sure ignition key cylinder is in Accessory posi-
tion. Cable will not adjust correctly in any
other position.
(3) Remove shi ft l ever bezel and consol e screws.
Rai se bezel and consol e for access to park i nterl ock
cabl e.
(4) Pul l cabl e l ock button up to rel ease cabl e (Fi g. 263).
(5) Pul l cabl e forward. Then rel ease cabl e and
press l ock button down unti l i t snaps i n pl ace.
BTSI FUNCTION CHECK
(1) Veri fy removal of i gni ti on key al l owed i n park
posi ti on onl y.
(2) When the shi ft l ever i s i n park, and the shi ft
handl e push-button i s i n the out posi ti on, the i gni -
ti on key cyl i nder shoul d rotate freel y from off to l ock.
When the shi fter i s i n any other posi ti on, the i gni ti on
key shoul d not rotate from off to l ock.
(3) Shi fti ng out of park shoul d be possi bl e when
the i gni ti on key cyl i nder i s i n the off posi ti on.
(4) Shi fti ng out of park shoul d not be possi bl e
whi l e appl yi ng 25 l b. max. handl e push-button force,
and i gni ti on key cyl i nder i s i n the run or start posi -
ti ons, unl ess the foot brake pedal i s depressed
approxi matel y 1/2 i nch (12mm).
(5) Shi fti ng out of park shoul d not be possi bl e
when the i gni ti on key cyl i nder i s i n the accessory or
l ock posi ti on.
(6) Shi fti ng between any gears neutral or park
may be done wi thout depressi ng foot brake wi th i gni -
ti on swi tch i n run or start posi ti ons and vehi cl e sta-
ti onary or i n moti on.
(7) The fl oorshi fter l ever and gate posi ti ons shoul d
be i n al i gnment wi th al l transmi ssi on detent posi -
ti ons.
(8) Engi ne starts must be possi bl e wi th fl oorshi ft
l ever i n park or neutral gate posi ti ons onl y. Engi ne
starts must not be possi bl e i n any other gate posi -
ti ons other than park or neutral .
(9) Wi th fl oorshi ft l ever handl e push-button not
depressed and l ever detent i n:
PARK POSI TI ON- appl y forward force on center
of handl e and remove pressure. Engi ne start must be
possi bl e.
PARK POSI TI ON- appl y rearward force on cen-
ter of handl e and remove pressure. Engi ne start
must be possi bl e.
NEUTRAL POSI TI ON- engi ne start must be
possi bl e.
Fig. 263 Shift And Park Lock Cables
PARK/INTER- LOCK CABLE SHIFT CABLE INTERLOCK CABLE LOCK BUTTON SHIFT LEVER AND HOUSING ASSEMBLY HOUSING MOUNT- ING COVER FLOORPAN FWD
21 - 102 TRANSMISSION AND TRANSFER CASE ZG
CLEANING AND INSPECTION (Continued)
NEUTRAL POSI TI ON, ENGI NE RUNNI NG
AND BRAKES APPLI ED- Appl y forward force on
center of shi ft handl e. Transmi ssi on shoul d not be
abl e to shi ft i nto reverse detent.
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 264). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A l ock button at the engi ne-end of the cabl e i s
provi ded for cabl e adjustment.
A correctl y adjusted throttl e val ve cabl e wi l l cause
the throttl e l ever on the transmi ssi on to move si mul -
taneousl y wi th the throttl e body l ever from the i dl e
posi ti on. Proper adjustment wi l l al l ow si mul taneous
movement wi thout causi ng the transmi ssi on throttl e
l ever to ei ther move ahead of, or l ag behi nd the l ever
on the throttl e body.
Chec king Throttle Valve Cable Adjustment
(1) Turn i gni ti on key to OFF posi ti on.
(2) Remove ai r cl eaner.
(3) Veri fy that l ever on throttl e body i s at curb i dl e
posi ti on. Then veri fy that transmi ssi on throttl e l ever
(Fi g. 265) i s al so at i dl e (ful l y forward) posi ti on.
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on.
I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
Throttle Valve Cable Adjustment Proc edure
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) I nsert a smal l screwdri ver under edge of
retai ni ng cl i p and remove retai ni ng cl i p.
(6) Center cabl e end on attachment stud to wi thi n
1 mm (0.039 i n.).
(7) I nstal l retai ni ng cl i p onto cabl e housi ng.
(8) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n Park
and Neutral . Adjustment i s OK i f the engi ne starts
onl y i n these posi ti ons. Adjustment i s i ncorrect i f the
engi ne starts i n one but not both posi ti ons. I f the
engi ne starts i n any posi ti on other than Park or Neu-
tral , or i f the engi ne wi l l not start at al l , the park/
neutral posi ti on swi tch may be faul ty.
Gearshift Adjustment Proc edure
(1) Shi ft transmi ssi on i nto Park.
(2) Rai se vehi cl e.
Fig. 264 Throttle Cable Attachment At Engine
TRANSMISSION THROTTLE VALVE CABLE ACCELERATOR CABLE CABLE ENGINE BRACKET
THROTTLE
BODY
FWD CABLEGUIDE
Fig. 265 Throttle Cable Attachment At Transmission
RETURN SPRING THROTTLE VALVE CABLE THROTTLE VALVE CABLE BRACKET THROTTLE VALVE LEVER GEAR SELEC- TOR LEVER SHIFT CABLE BRACKET
ZG TRANSMISSION AND TRANSFER CASE 21 - 103
ADJ USTMENTS (Continued)
(3) Rel ease cabl e adjuster cl amp (at transmi ssi on
end of cabl e) to unl ock cabl e.
(4) Unsnap cabl e from cabl e mounti ng bracket on
transmi ssi on (Fi g. 266).
(5) Sl i de cabl e eyel et off transmi ssi on shi ft l ever.
(6) Veri fy transmi ssi on shi ft l ever i s i n Park
detent by movi ng l ever ful l y rearward. Last rearward
detent i s Park posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Sl i de cabl e eyel t onto transmi ssi on shi ft l ever.
(9) Snap shi ft cabl e adjuster i nto mounti ng
bracket on transmi ssi on.
(10) Lock shi ft cabl e by pressi ng cabl e adjuster
cl amp down unti l i t snaps i nto pl ace.
(11) Lower vehi cl e and check engi ne starti ng.
Engi ne shoul d start onl y i n Park and Neutral .
BAND ADJUSTMENTS
FRONT BAND ADJ USTMENT
The front (ki ckdown) band adjusti ng screw i s
l ocated on the l eft si de of the transmi ssi on case
above the manual val ve and throttl e val ve l evers.
(1) Rai se vehi cl e.
(2) Loosen band adjusti ng screw l ocknut (Fi g. 267).
Then back l ocknut off 3-5 turns. Be sure adjusti ng
screw turns freel y i n case. Appl y l ubri cant to screw
threads i f necessary.
(3) Ti ghten band adjusti ng screw to 8 Nm (72 i n.
l bs.) torque wi th I nch Pound Torque Wrench
C-3380-A, a 3-i n. extensi on and 5/16 socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw (Fig. 268), tighten the screw to only
5 Nm (47-50 in. lbs.) torque.
42RE TRANSMISSION
Back off front band adjusti ng screw 3-5/8 turns.
Hol d adjuster screw i n posi ti on and ti ghten l ock-
nut to 41 Nm (30 ft. l bs.) torque.
44RE TRANSMISSION
Back off front band adjusti ng screw 2-1/4 turns.
Hol d adjuster screw i n posi ti on and ti ghten l ock-
nut to 41 Nm (30 ft. l bs.) torque.
(4) Lower vehi cl e.
REAR BAND ADJ USTMENT
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(1) Rai se vehi cl e.
(2) Remove transmi ssi on oi l pan and drai n fl ui d.
(3) Loosen band adjusti ng screw l ocknut 5-6 turns (Fi g.
269). Be sure adjusti ng screw turns freel y i n l ever.
(4) Ti ghten adjusti ng screw to 8 Nm (72 i n. l bs.)
torque.
42RE TRANSMISSION
Back off adjusti ng screw 4 turns.
Fig. 266 Shift Cable Attachment At Transmission
THROTTLE VALVE CABLE TRANSMISSION SHIFT LEVER SHIFT CABLE SHIFT CABLE BRACKET
Fig. 267 Front Band Adjustment Screw Location
FRONT BAND ADJUSTING SCREW LOCK NUT MANUAL LEVER SHAFT PARK/NEU- TRAL POSI- TION SWITCH
Fig. 268 Band Adjustment Adapter Tool
INCH-POUND TORQUE WRENCH 5/16 SOCKET ADAPTER C-3705 (TIGHTEN ADJUSTING SCREW TO ONLY 5 Nm/50 IN-LBS IF ADAPTER IS USED)
21 - 104 TRANSMISSION AND TRANSFER CASE ZG
ADJ USTMENTS (Continued)
Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 Nm (25 ft. l bs.) torque.
44RE TRANSMISSION
Back off adjusti ng screw 4 turns.
Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 Nm (25 ft. l bs.) torque.
(5) Posi ti on new gasket on oi l pan and i nstal l pan
on transmi ssi on. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.) torque.
(6) Lower vehi cl e and refi l l transmi ssi on wi th
Mopar ATF Pl us, Type 7176 fl ui d.
VALVE BODY
CONTROL PRESSURE ADJ USTMENTS
There are two control pressure adjustments on the
val ve body;
Li ne Pressure
Throttl e Pressure
Li ne and throttl e pressures are i nterdependent
because each affects shi ft qual i ty and ti mi ng. As a
resul t, both adjustments must be performed properl y
and i n the correct sequence. Adjust l i ne pressure fi rst
and throttl e pressure l ast.
LINE PRESSURE ADJUSTMENT
Measure di stance from the val ve body to the i nner
edge of the adjusti ng screw wi th an accurate steel
scal e (Fi g. 270).
Di stance shoul d be 33.4 mm (1-5/16 i n.).
I f adjustment i s requi red, turn the adjusti ng screw
i n, or out, to obtai n requi red di stance setti ng.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One compl ete turn of the adjusti ng screw changes
l i ne pressure approxi matel y 1-2/3 psi (9 kPa).
Turni ng the adjusti ng screw countercl ockwi se
i ncreases pressure whi l e turni ng the screw cl ockwi se
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
I nsert Gauge Tool C-3763 between the throttl e
l ever cam and the ki ckdown val ve stem (Fi g. 271).
Push the gauge tool i nward to compress the ki ck-
down val ve agai nst the spri ng and bottom the throt-
tl e val ve.
Mai ntai n pressure agai nst ki ckdown val ve spri ng.
Turn throttl e l ever stop screw unti l the screw head
touches throttl e l ever tang and the throttl e l ever cam
touches gauge tool .
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
Fig. 269 Rear Band Adjusting Screw Location
ADJUSTING SCREW REAR BAND LEVER LOCKNUT
Fig. 270 Line Pressure Adjustment
WRENCH 15/16 INCH
Fig. 271 Throttle Pressure Adjustment
HEX WRENCH (IN THROT- TLE LEVER ADJUSTING SCREW) SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE LEVER AND KICKDOWN VALVE)
ZG TRANSMISSION AND TRANSFER CASE 21 - 105
ADJ USTMENTS (Continued)
H
Y
D
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A
U
L
I
C
F
L
O
W
I
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P
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K
21 - 106 TRANSMISSION AND TRANSFER CASE ZG
SCHEMATICS AND DIAGRAMS (Continued)
H
Y
D
R
A
U
L
I
C
F
L
O
W
I
N
N
E
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T
R
A
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ZG TRANSMISSION AND TRANSFER CASE 21 - 107
SCHEMATICS AND DIAGRAMS (Continued)
H
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D
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A
U
L
I
C
F
L
O
W
I
N
R
E
V
E
R
S
E
21 - 108 TRANSMISSION AND TRANSFER CASE ZG
SCHEMATICS AND DIAGRAMS (Continued)
H
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D
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F
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I
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D
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ZG TRANSMISSION AND TRANSFER CASE 21 - 109
SCHEMATICS AND DIAGRAMS (Continued)
H
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F
L
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W
I
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D
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21 - 110 TRANSMISSION AND TRANSFER CASE ZG
SCHEMATICS AND DIAGRAMS (Continued)
H
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D
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C
F
L
O
W
I
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D
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T
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ZG TRANSMISSION AND TRANSFER CASE 21 - 111
SCHEMATICS AND DIAGRAMS (Continued)
H
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D
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I
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)
21 - 112 TRANSMISSION AND TRANSFER CASE ZG
SCHEMATICS AND DIAGRAMS (Continued)
H
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D
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C
F
L
O
W
I
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D
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ZG TRANSMISSION AND TRANSFER CASE 21 - 113
SCHEMATICS AND DIAGRAMS (Continued)
H
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D
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A
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F
L
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I
N
M
A
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(
1
)
21 - 114 TRANSMISSION AND TRANSFER CASE ZG
SCHEMATICS AND DIAGRAMS (Continued)
H
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D
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A
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F
L
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I
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(
2
)
ZG TRANSMISSION AND TRANSFER CASE 21 - 115
SCHEMATICS AND DIAGRAMS (Continued)
H
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F
L
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D
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21 - 116 TRANSMISSION AND TRANSFER CASE ZG
SCHEMATICS AND DIAGRAMS (Continued)
SPECIFICATIONS
TRANSMISSION
GENERAL
GEAR RATIOS
1ST GEAR-2.74
2ND GEAR-1.54
3RD GEAR-1.00
4TH GEAR-0.69
REV.GEAR-2.21
TORQUE
DESCRIPTION TORQUE
Fi tti ng, cool er l i ne at trans . . . . . 18 Nm (13 ft. l bs.)
Bol t, torque convertor . . . . . . . . . 31 Nm (23 ft. l bs.)
Bol t/nut, crossmember . . . . . . . . 68 Nm (50 ft. l bs.)
Bol t, dri vepl ate to crankshaft . . . 75 Nm (55 ft. l bs.)
Pl ug, front band reacti on . . . . . . 17 Nm (13 ft. l bs.)
Locknut, front band adj. . . . . . . . 34 Nm (25 ft. l bs.)
Swi tch, park/neutral . . . . . . . . . . 34 Nm (25 ft. l bs.)
Bol t, fl ui d pan . . . . . . . . . . . . . . 17 Nm (13 ft. l bs.)
Screws, fl ui d fi l ter . . . . . . . . . . . . 4 Nm (35 i n. l bs.)
Bol t, oi l pump . . . . . . . . . . . . . . . 20 Nm (15 ft. l bs.)
Bol t, overrunni ng cl utch cam . . . 17 Nm (13 ft. l bs.)
Bol t, O/D to trans. . . . . . . . . . . . 34 Nm (25 ft. l bs.)
Bol t, O/D pi ston retai ner . . . . . . 17 Nm (13 ft. l bs.)
Pl ug, pressure test port . . . . . . . 14 Nm (10 ft. l bs.)
Bol t, reacti on shaft support . . . . 20 Nm (15 ft. l bs.)
Locknut, rear band . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bol t. speedometer adapter . . . . . . 11 Nm (8 ft. l bs.)
Bol t, val ve body to case . . . . . . 12 Nm (100 i n. l bs.)
Sensor, trans speed . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Screw, sol enoi d wi ri ng connector . 4 Nm (35 i n. l bs.)
Screw, sol enoi d to transfer pl ate . 4 Nm (35 i n. l bs.)
Component Metric Inch
Planetary end play 0.127-1.22
mm
0.005-0.048
in.
Input shaft end play 0.56-2.31
mm
0.022-0.091
in.
Clutch pack clearance/
Front.
1.70-
3.40mm
0.067-0.134
in.
Clutch pack clearance/
Rear.
0.81-1.40
mm
0.022-0.037
in.
Front Clutch 42RE-4 discs
44RE-5 discs
Rear Clutch 42RE and 44RE-4 discs
Overdrive clutch disc
usage
42RE-3 discs
44RE-4 discs
Direct clutch disc
usage
42RE-6 discs
44RE-8 discs
42RE Band
adjustment from 72 in.
lbs.
Front band Back off 3-5/8 turns
Rear band Back off 4 turns
44RE Band
adjustment from 72 in.
lbs.
Front band Back off 2-1/4 turns
Rear band Back off 4 turns
Recommended fluid Mopar ATF Plus type 7176
ZG TRANSMISSION AND TRANSFER CASE 21 - 117
THRUST WASHER/SPACER/SNAP RING DIMENSIONS
PRESSURE TEST
Component Metric Inch
Front clutch thrust washer (reaction shaft
support hub)
1.55 mm 0.061 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) 1.5-1.6 mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) Select fit to set end play
Rear clutch pack snap ring 1.5 mm 0.060 in.
1.95 mm 0.076 in.
2.45 mm 0.098 in.
Planetary geartrain snap ring (at front of output shaft) Select fit (three thicknesses avalible)
Overdrive piston thrust plate Thrust plate and spacer are select fit. Refer to
size charts and selection procedures in
Overdrive Unit D&A procedures
Intermiediate shaft spacer
Overdrive clutch Fourth gear only Pressure should be 469-496 kPa (68-72 psi) with
closed throttle and increase to 620-896 kPa (90-130
psi) at 1/2 to 3/4 throttle.
Line pressure (at
accumulator)
Closed throttle 372-414 kPa (54-60 psi).
Front servo Third gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
Governor D range closed throttle Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.
21 - 118 TRANSMISSION AND TRANSFER CASE ZG
SPECIFICATIONS (Continued)
SPECIAL TOOLS
RE TRANSMISSIONS
Spring Compressor and Alignment Shaft6227
Gauge Bar6311
Extension Housing PilotC-3288-B
Pressure GaugeC-3292
Pressure GaugeC-3293SP
Dial IndicatorC-3339
Spring CompressorC-3422-B
ZG TRANSMISSION AND TRANSFER CASE 21 - 119
Puller, Slide HammerC-3752
Gauge, Throttle SettingC-3763
Seal InstallerC-3860A
Seal RemoverC-3985-B
InstallerC-3995-A
Universal HandleC-4171
Seal InstallerC-4193-A
Dial CaliperC-4962
21 - 120 TRANSMISSION AND TRANSFER CASE ZG
SPECIAL TOOLS (Continued)
Bushing Remover/Installer SetC-3887-J
Nut, Bushing RemoverSP-1191,From kit C-3887-J
Cup, Bushing RemoverSP-3633,From kit C-3887-J
Remover, BushingSP-3551
Installer, BushingSP-5117
Remover, BushingSP-5324
Installer, BushingSP-5325
Compressor, SpringC-3575-A
ZG TRANSMISSION AND TRANSFER CASE 21 - 121
SPECIAL TOOLS (Continued)
Gauge6312
AdapterC-3705
Flusher6906
Installer8114
Remover6957
Installer6951
Retainer6583
21 - 122 TRANSMISSION AND TRANSFER CASE ZG
SPECIAL TOOLS (Continued)
NV242 TRANSFER CASE
INDEX
page page
GENERAL INFORMATION
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . 123
RECOMMENDED LUBRICANT AND FILL LEVEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
TRANSFER CASE IDENTIFICATION . . . . . . . . 124
DIAGNOSIS AND TESTING
NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 125
REMOVAL AND INSTALLATION
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . 128
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . 127
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . 127
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . 126
DISASSEMBLY AND ASSEMBLY
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . 129
CLEANING AND INSPECTION
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . 149
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . 151
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
SPECIAL TOOLS
SPECIAL TOOLSNV242 . . . . . . . . . . . . . . . 152
GENERAL INFORMATION
NV242 TRANSFER CASE
The NV242 i s a ful l and part-ti me transfer case
(Fi g. 1). I t provi des ful l ti me 2-wheel , or 4-wheel
dri ve operati on.
A di fferenti al i n the transfer case i s used to control
torque transfer to the front and rear axl es. A l ow
range gear provi des i ncreased l ow speed torque capa-
bi l i ty for off road operati on. The l ow range provi des a
2.72:1 reducti on rati o.
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. I t dri ves the mai nshaft through the pl an-
etary gear and range hub. The front output shaft i s
operated by a dri ve chai n that connects the shaft to a
dri ve sprocket on the mai nshaft. The dri ve sprocket
i s engaged/di sengaged by the mode fork, whi ch oper-
ates the mode sl eeve and hub. The sl eeve and hub
are not equi pped wi th a synchro mechani sm for shi ft-
i ng.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
NV242 operati ng ranges are 2WD (2-wheel dri ve),
4x4 part-ti me, 4x4 ful l ti me, and 4 Lo.
The 2WD and 4x4 ful l ti me ranges can be used at
any ti me and on any road surface.
The 4x4 part-ti me and 4 Lo ranges are for off road
use onl y. The onl y ti me these ranges can be used on
hard surface roads, i s when the surface i s covered
wi th snow and i ce.
Fig. 1 NV242 Transfer Case
ZG TRANSMISSION AND TRANSFER CASE 21 - 123
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a fl oor mounted
shi ft l ever. The shi ft l ever i s connected to the trans-
fer case range l ever by an adjustabl e l i nkage rod. A
strai ght l i ne shi ft pattern i s used. Range posi ti ons
are marked on the shi fter bezel cover pl ate, or on the
shi ft knob.
TRANSFER CASE IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 2). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
RECOMMENDED LUBRICANT AND FILL LEVEL
Recommended l ubri cant for the NV242 transfer
case i s Mopar Dexron I I , or ATF Pl us. Approxi mate
l ubri cant fi l l capaci ty i s 1.35 l i ters (2.85 pi nts).
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 2). Correct fi l l l evel i s to the bottom edge of the
fi l l pl ug hol e. Be sure the vehi cl e i s l evel to ensure
an accurate fl ui d l evel check.
Fig. 2 Fill/Drain Plug And I.D. Tag Locations
21 - 124 TRANSMISSION AND TRANSFER CASE ZG
GENERAL INFORMATION (Continued)
DIAGNOSIS AND TESTING
NV242 DIAGNOSIS
Condition Possible Cause Correction
TRANSFER CASE DIFFICULT TO
SHIFT OR WILL NOT SHIFT INTO
DESIRED RANGE
(1) Transfer case external shift
linkage binding.
(1) Lubricate, repair or replace
linkage, or tighten loose
components as necessary.
(2) Insufficient or incorrect lubricant. (2) Drain and refill to edge of fill
hole with DEXRONII or MOPAR-
MERCON Automatic Transmissin
Fluid.
(3) Internal components binding,
worn or damaged.
(3) Disassemble unit and replace
worn or damaged components as
necessary.
TRANSFER CASE NOISY IN ALL
DRIVE POSITIONS
(1) Insufficient or incorrect lubricant. (1) Drain and refill to edge of fill
hole with DEXRONII or MOPAR-
MERCON Automatic Transmissin
Fluid. Check for leaks and repair if
necessary. Note: If unit is still
noisy after drain and refill,
disassembly and inspection may
be required to locate source of
noise.
LUBRICANT LEAKING FROM
OUTPUT SHAFT SEALS OR FROM
VENT
(1) Transfer case overfilled. (1) Drain to correct level.
(2) Vent closed or restricted. (2) Clear or replace vent if
necessary.
(3) Output shaft seals damaged or
installed incorrectly.
(3) Replace seals. Be sure seal lip
faces interior of case when installed.
Also be sure yoke seal surfaces are
not scored or nicked. Remove
scores and nicks with fine
sandpaper or replace yoke(s) if
necessary.
TRANSFER CASE WILL NOT
SHIFT THROUGH 4 X 4 PART-
TIME RANGE (Light Remains On)
(1) Incomplete shift due to
drivetrain torque load.
(1) Driver must momentarily release
the accelerator pedal to complete
the shift.
(2) Incorrect tire pressure(s). (2) Inflate all tires equally to correct
pressure.
(3) Excessive tire wear. (3) Switch tiresInstall the two tires
with the most wear (one on the front
axle and one on the rear axle).
(4) Excessive vehicle loading. (4) Check vehicle loading Do not
exceed the vehicles GVW.
ZG TRANSMISSION AND TRANSFER CASE 21 - 125
REMOVAL AND INSTALLATION
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(2) Rai se vehi cl e.
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
al i gnment reference.
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember, or ski d pl ate.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 3)
and i ndi cator swi tch harness, i f necessary.
(11) Support transfer case wi th transmi ssi on jack.
(12) Secure transfer case to jack wi th chai ns.
(13) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(2) Secure transfer case to jack wi th chai ns.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (26 ft. l bs.) torque (Fi g. 3).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch, i f necessary. Secure wi re harness to cl i ps
on transfer case.
(8) Al i gn and connect propel l er shafts. Ti ghten
shaft attachi ng bol ts to 19 Nm (170 i n. l bs.) torque.
(9) Fi l l transfer case wi th correct fl ui d. Refer to
Recommended Lubri cant And Fi l l Level secti on for
proper fl ui d and capaci ty.
Fig. 3 Transfer Case Mounting
VENT TUBE TRANSFER CASE TRANSMISSION
21 - 126 TRANSMISSION AND TRANSFER CASE ZG
(10) I nstal l rear crossmember, or ski d pl ate.
Ti ghten crossmember bol ts to 41 Nm (30 ft. l bs.)
torque.
(11) Remove transmi ssi on jack and support stand.
(12) Connect shi ft rod to transfer case range l ever.
(13) Adjust transfer case shi ft l i nkage.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(2) Rai se vehi cl e.
(3) Loosen adjusti ng trunni on l ocknut and sl i de
shi ft rod out of trunni on (Fi g. 4). I f rod l acks enough
travel to come out of trunni on, push trunni on out of
torque shaft.
(4) Lower vehi cl e.
(5) Remove consol e. Refer to Group 23, Body, for
proper procedures.
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. Refer to Group 23, Body, for
proper procedures.
(3) Rai se vehi cl e.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
(6) Lower vehi cl e and check transfer case shi ft
operati on.
SPEEDOMETER
REMOVAL
(1) Rai se vehi cl e.
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 5).
(4) Remove speed sensor and speedometer adapter
as an assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
Fig. 4 Shift Linkage
TORQUE
(2735 in. lbs.)
(97123 in. lbs.)
(72120 in. lbs.)
RIVNUT (4) SHIFT LEVER ASSEMBLY FLOORPAN TRUNNION LOCK BOLT SELECTOR ROD AND TRUN- NION SHIFT LEVER ROD TORQUE SHAFT FRAME BRACKET TORQUE SHAFT TRANSFER CASE SHIFT LEVER TORQUE SHAFT TRANSFER CASE BRACKET
ZG TRANSMISSION AND TRANSFER CASE 21 - 127
REMOVAL AND INSTALLATION (Continued)
(6) Remove speedometer pi ni on from adapter.
Repl ace pi ni on i f chi pped, cracked, or worn.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 5).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
severel y corroded, or damaged.
INSTALLATION AND INDEXING
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter (Fi g. 5), i f necessary.
(3) Lubri cate sensor and adapter O-ri ngs wi th
transmi ssi on fl ui d.
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 Nm
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 6).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 Nm (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel i f necessary.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove front propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
7).
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 6952-A as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
ITEM TORQUE
A 2-3 Nm (15-27 in. lbs.)
B 10-12 Nm (90-110 in. lbs.)
Fig. 5 Speedometer Components
ITEM
TORQUE SENSOR O-RING SPEEDOMETER ADAPTER ADAPTER O-RING SPEEDOMETER PINION ADAPTER CLAMP VEHICLE SPEED SENSOR
21 - 128 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 8). Once seal i s started, conti nue tappi ng
seal i nto bore unti l i nstal l er tool seats agai nst case.
DISASSEMBLY AND ASSEMBLY
NV242 TRANSFER CASE
DISASSEMBLY
REAR RETAINER REMOVAL
(1) Remove output shaft boot. Spread band cl amp
that secures boot on sl i nger wi th a sui tabl e awl .
Then sl i de boot off shaft (Fi g. 9).
(2) Usi ng pul l er MD-998056-A, remove rear sl i nger
(Fi g. 10).
(3) Remove sl i nger stop spacer and snap-ri ng from
output shaft (Fi g. 11).
(4) Remove rear seal from retai ner (Fi g. 12). Use
pry tool , or col l apse seal wi th punch to remove i t.
(5) Remove rear output beari ng I .D. retai ni ng ri ng
(Fi g. 13).
(6) Remove speedometer adapter.
(7) Remove rear retai ner bol ts.
Fig. 6 Location Of Index Numbers On
SpeedometerAdapter
SPEEDOMETER ADAPTER INDEX NUMBER LOCA- TION
Fig. 7 Remove Front Output Shaft Seal
OUTPUT SHAFTSEAL PRYBAR
Fig. 8 Front Output Seal Installation
INSTALLER 6952A TRANSFER CASE
Fig. 9 Output BootTypical
SLINGER BOOT AWL TRANSFER CASE
Fig. 10 Rear Slinger Removal
TRANSFER CASE SPECIAL TOOL MD998056A SLINGER
ZG TRANSMISSION AND TRANSFER CASE 21 - 129
REMOVAL AND INSTALLATION (Continued)
(8) Remove rear retai ner. Tap retai ner wi th mal l et
and pry upward to break seal er bead. Then sl i de
retai ner off case and output shaft (Fi g. 14).
(9) Remove rear beari ng O.D. retai ni ng ri ng wi th
snap ri ng pl i ers. Then ti l t pump and sl i de i t off out-
put shaft (Fi g. 15)
(10) Remove pi ckup tube O-ri ng from pump (Fi g.
16) but do not di sassembl e pump; i t i s not a repai r-
abl e part.
(11) Remove seal from oi l pump wi th pry tool .
(12) Remove bol ts attachi ng rear case to front case
(Fi g. 17). Note posi ti on of the two bl ack fi ni sh bol ts at
each end of the case. These bol ts go through the case
dowel s and requi re a washer under the bol t head.
(13) Remove rear case from front case (Fi g. 18).
I nsert screwdri vers i nto sl ots cast i nto each end of
Fig. 11 Slinger Stop Spacer and Snap-ring
SNAP-RING OUTPUT SHAFT STOP SPACER SEAL
Fig. 12 Rear Seal Removal
REAR RETAINER OUTPUT SHAFT SEAL
Fig. 13 Rear Bearing I.D. Retaining RingRemoval
SNAP RING PLIERS REAR BEARING I.D. RETAIN- ING RING
Fig. 14 Rear Retainer Removal
MAINSHAFT REAR RETAINER
Fig. 15 Oil Pump Removal
OIL PUMP
Fig. 16 Pickup Tube O-Ring Location
OIL PUMP O-RING
21 - 130 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
case. Then pry upward to break seal er bead and
remove rear case.
CAUTION: Do not pry on the sealing surface of either
case half as the surfaces will become damaged.
(14) Remove oi l pi ckup tube and screen from rear
case (Fi g. 19).
YOKE AND RANGE LEVER REMOVAL
(1) Remove front yoke nut:
(a) Move range l ever to 4L posi ti on.
(b) Remove nut wi th socket and i mpact wrench
(Fi g. 20).
(2) Remove yoke. I f yoke i s di ffi cul t to remove by
hand, remove i t wi th beari ng spl i tter, or wi th stan-
dard two jaw pul l er (Fi g. 21). Be sure pul l er tool i s
posi ti oned on yoke and not on sl i nger as sl i nger wi l l
be damaged.
(3) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(4) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft (Fi g. 22).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Remove dri ve sprocket snap-ri ng (Fi g. 23).
(2) Remove dri ve sprocket and chai n (Fi g. 24).
(3) Remove front output shaft (Fi g. 25).
Fig. 17 Spline And Dowel Bolt Locations
DOWEL BOLT AND WASHER (2) CASE BOLT (5) SPLINE HEAD BOLT (1)
Fig. 18 Loosening/Removing Rear case
MAINSHAFT SCREWDRIVER FRONT CASE SCREWDRIVER REAR CASE
Fig. 19 Oil Pickup Screen, Hose And TubeRemoval
CONNECTING HOSE PICKUP SCREEN PICKUP TUBE
Fig. 20 Yoke Nut Removal
IMPACT WRENCH SOCKET YOKE
Fig. 21 Yoke Removal
PULLERTOOL YOKE
ZG TRANSMISSION AND TRANSFER CASE 21 - 131
DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT FORKS AND MAINSHAFT REMOVAL AND
DISASSEMBLY
(1) Remove shi ft detent pl ug, spri ng and pi n (Fi g.
26).
(2) Remove seal pl ug from l ow range fork l ockpi n
access hol e. Then move shi ft sector to al i gn l ow range
fork l ockpi n wi th access hol e.
(3) Remove range fork l ockpi n wi th si ze number
one easy-out tool as fol l ows:
(a) I nsert easy-out tool through access hol e i n
si de of transfer case and i nto l ock-pi n.
(b) Tap easy-out tool i nto l ock-pi n wi th hammer
unti l tool i s securel y engaged i nto the l ock-pi n.
(c) I nstal l a t-handl e, such as from a tap and di e
set, onto the easy-out tool .
(d) Securel y ti ghten the t-handl e onto the tool .
Fig. 22 Range Lever Removal
RANGE LEVER SECTORSHAFT
Fig. 23 Drive Sprocket Snap-Ring Removal
DRIVE SPROCKET DRIVE SPROCKET SNAP RING
Fig. 24 Drive Sprocket And Chain Removal
DRIVE SPROCKET DRIVE CHAIN
Fig. 25 Removing Front Output Shaft
FRONT OUTPUT SHAFT
Fig. 26 Detent Component Removal
PLUNGER O-RING PLUG SPRING
21 - 132 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(e) I n one moti on, pul l upward and turn the
t-handl e counter-cl ockwi se to remove the l ock-pi n.
(4) Remove shi ft rai l by pul l i ng i t strai ght up and
out of fork (Fi g. 27).
(5) Remove mode fork and mai nshaft as assembl y
(Fi g. 28).
(6) Remove mode shi ft sl eeve and mode fork
assembl y from mai nshaft (Fi g. 29). Note posi ti on of
mode sl eeve i n fork and remove sl eeve.
(7) Remove i ntermedi ate cl utch shaft snap-ri ng
(Fi g. 30).
Fig. 27 Shift Rail Removal
SHIFT RAIL MODE FORK
Fig. 28 Mode Fork And Mainshaft Removal
MAINSHAFT ASSEMBLY MODE FORK
Fig. 29 Mode Fork And Sleeve Removal
MAINSHAFT SLEEVE MODE FORK ASSEMBLY
Fig. 30 Intermediate Clutch Shaft Snap-
RingRemoval
SNAP RING INTERMEDIATE CLUTCH SHAFT
ZG TRANSMISSION AND TRANSFER CASE 21 - 133
DISASSEMBLY AND ASSEMBLY (Continued)
(8) Remove cl utch shaft thrust ri ng (Fi g. 31).
(9) Remove i ntermedi ate cl utch shaft (Fi g. 32).
(10) Remove di fferenti al snap-ri ng (Fi g. 33).
(11) Remove di fferenti al (Fi g. 34).
(12) Remove di fferenti al needl e beari ngs and both
needl e beari ng thrust washers from mai nshaft.
Fig. 31 Clutch Shaft Thrust Ring Removal
CLUTCH SHAFT THRUSTRING
Fig. 32 Intermediate Clutch Shaft Removal
INTERMEDIATE CLUTCH SHAFT
Fig. 33 Differential Snap-Ring Removal
DIFFERENTIAL SNAP RING
Fig. 34 Differential Removal
DIFFERENTIAL MAINSHAFT
21 - 134 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(13) Sl i de l ow range fork pi n out of shi ft sector sl ot
(Fi g. 35).
(14) Remove l ow range fork and hub (Fi g. 36).
(15) Remove shi ft sector (Fi g. 37).
(16) Remove shi ft sector bushi ng and O-ri ng (Fi g.
38).
INPUT GEAR/LOW RANGE ASSEMBLY REMOVAL AND
DISASSEMBLY
(1) Remove front beari ng retai ner bol ts.
(2) Remove front beari ng retai ner. Careful l y pry
retai ner l oose wi th screwdri ver (Fi g. 39). Posi ti on
screwdri ver i n sl ots cast i nto retai ner.
(3) Remove i nput gear snap-ri ng (Fi g. 40).
(4) Remove i nput/l ow range gear assembl y from
beari ng wi th Tool Handl e C-4171 and Tool 7829A
(Fi g. 41).
(5) Remove l ow range gear snap-ri ng (Fi g. 42).
Fig. 35 Disengaging Low Range Fork
SHIFT SECTOR LOW RANGE FORK PIN SLOT
Fig. 36 Low Range Fork And Hub Removal
LOW RANGE FORK FORK HUB
Fig. 37 Shift Sector Position
SHIFT SECTOR LOW RANGE FORK PIN SLOT
Fig. 38 Sector Bushing And O-Ring Removal
SHIFT SEC- TOR BUSHING O-RING
ZG TRANSMISSION AND TRANSFER CASE 21 - 135
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Remove i nput gear retai ner, thrust washers
and i nput gear from l ow range gear (Fi g. 43).
(7) I nspect l ow range annul us gear (Fi g. 44). Gear
is not a serviceable component. If damaged,
replace gear and front case as assembly.
(8) Remove oi l seal s from fol l owi ng components:
front beari ng retai ner.
rear retai ner.
oi l pump.
case hal ves.
DIFFERENTIAL DISASSEMBLY
(1) Mark di fferenti al case hal ves for reference.
(2) Remove di fferenti al case bol ts.
(3) I nvert di fferenti al on workbench.
Fig. 39 Front Bearing Retainer Removal
FRONT BEARING RETAINER RETAINER SLOT
Fig. 40 Input Gear Snap-Ring Removal
INPUT GEAR SNAP RING
Fig. 41 Input And Low Range Gear
AssemblyRemoval
INPUT-LOW RANGE GEARS SPECIAL TOOL 7829A SPECIAL TOOL C-4171
Fig. 42 Low Range Gear Snap-Ring Removal/
Installation
LOW RANGE GEAR SNAP RING
21 - 136 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Separate top case from bottom case. Use sl ots
i n case hal ves to pry them apart (Fi g. 45).
(5) Remove thrust washers and pl anet gears from
case pi ns (Fi g. 46).
Fig. 43 Low Range Gear Disassembly
THRUST WASHERS LOW RANGE GEAR INPUTGEAR RETAINER
Fig. 44 Inspecting Low Range Annulus Gear
LOW RANGE ANNULUS GEAR
Fig. 45 Separating Differential Case Halves
TOP CASE CASE BOLTS CASE BOLTS CASE SLOTS CASE BOLTS
Fig. 46 Planet Gears And Thrust Washer Removal
BOTTOM CASE THRUST WASHERS (12) PLANET GEARS (6)
ZG TRANSMISSION AND TRANSFER CASE 21 - 137
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Remove mai nshaft and sprocket gears from
bottom case (Fi g. 47). Note gear posi ti on for reference
before separati ng them.
ASSEMBLY
Lubri cate transfer case components wi th automati c
transmi ssi on fl ui d or petrol eum jel l y (where i ndi -
cated) duri ng assembl y.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
BEARING AND SEAL INSTALLATION
(1) Remove snap-ri ng that retai ns front output
shaft front beari ng i n case (Fi g. 48). Then remove
beari ng. Use hammer handl e, or hammer and brass
punch to tap beari ng out of case.
(2) I nstal l new front output shaft front beari ng
wi th Tool Handl e C-4171 and I nstal l er 8033A wi th
the tapered cone upward (Fi g. 49).
(3) I nstal l front beari ng snap-ri ng (Fi g. 48).
(4) Remove front output shaft seal usi ng an appro-
pri ate pry tool (Fi g. 50) or sl i de-hammer mounted
screw.
Fig. 47 Mainshaft And Sprocket Gear Removal
MAINSHAFT GEAR SPROCKETGEAR BOTTOM CASE
Fig. 48 Front Output Shaft Front BearingSnap-Ring
Removal
FRONT BEARING SNAP RING
Fig. 49 Front Output Shaft Front BearingInstallation
SPECIAL TOOL C-4171 SPECIAL TOOL 8033A
21 - 138 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(5) I nstal l new front output shaft oi l seal wi th
I nstal l er 6952-A (Fi g. 51).
(6) Remove i nput gear beari ng wi th Tool Handl e
C-4171 and Remover C-4210 (Fi g. 52).
(7) I nstal l snap-ri ng on new i nput gear beari ng.
(8) I nstal l new i nput gear beari ng wi th Tool Han-
dl e C-4171 and Remover C-4210. I nstal l beari ng far
enough to seat snap-ri ng agai nst case (Fi g. 53).
(9) Remove the i nput gear pi l ot beari ng by i nsert-
i ng a sui tabl y si zed dri ft i nto the spl i ned end of the
i nput gear and dri vi ng the beari ng out wi th the dri ft
and a hammer (Fi g. 54).
Fig. 50 Remove Front Output Shaft Seal
OUTPUT SHAFTSEAL PRYBAR
Fig. 51 Install Front Output Shaft Seal
INSTALLER 6952A TRANSFER CASE
Fig. 52 Input Gear Bearing Removal
SPECIAL TOOL C-4171SPECIAL TOOL C-4210
Fig. 53 Seating Input Gear Bearing
SNAP RING INPUT SHAFT BEARING
Fig. 54 Remove Input Gear Pilot Bearing
DRIFT INPUT GEAR
ZG TRANSMISSION AND TRANSFER CASE 21 - 139
DISASSEMBLY AND ASSEMBLY (Continued)
(10) I nstal l new pi l ot beari ng wi th I nstal l er 8128
and Handl e C-4171 (Fi g. 55).
(11) I nstal l new seal i n front beari ng retai ner wi th
I nstal l er 7884 (Fi g. 56).
(12) Remove output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 57).
(13) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 58). Lubri cate beari ng after
i nstal l ati on.
Fig. 55 Install Input Gear Pilot Bearing
HANDLE C-4171 INSTALLER 8128 INPUT GEAR
Fig. 56 Front Bearing Retainer Seal Installation
FRONT BEARING RETAINER SPECIAL TOOL 7884
Fig. 57 Remove Front Output Shaft Rear Bearing
REAR CASE SPECIAL TOOL L-44541 AND L-44543 SPECIAL TOOL 8148
Fig. 58 Install Front Putput Shaft Rear Bearing
HANDLE C-4171 OUTPUT SHAFT INNER BEARING INSTALLER 5066
21 - 140 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(14) I nstal l new seal i n oi l pump feed housi ng wi th
Speci al Tool 7888 (Fi g. 59).
(15) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 60).
DIFFERENTIAL ASSEMBLY
(1) Lubri cate di fferenti al components wi th auto-
mati c transmi ssi on fl ui d.
(2) I nstal l sprocket gear i n di fferenti al bottom case
(Fi g. 61).
(3) I nstal l di fferenti al pl anet gears and new thrust
washers (Fi g. 62). Be sure thrust washers are
installed at top and bottom of each planet gear.
(4) I nstal l di fferenti al mai nshaft gear (Fi g. 62).
(5) Al i gn and posi ti on di fferenti al top case on bot-
tom case (Fi g. 63). Al i gn usi ng scri be marks made at
di sassembl y.
(6) Whi l e hol di ng di fferenti al case hal ves together,
i nvert the di fferenti al and start the di fferenti al case
bol ts.
(7) Ti ghten di fferenti al case bol ts to speci fi ed
torque.
Fig. 59 Oil Pump Seal Installation
HOUSINGSEAL SPECIAL TOOL 7888 OIL PUMP FEED HOUSING
Fig. 60 Pickup Tube O-Ring Installation
PICKUP TUBE O-RING
Fig. 61 Installing Differential SprocketGear
SPROCKETGEAR BOTTOMCASE
Fig. 62 Installing Mainshaft And Planet Gears
MAINSHAFT GEAR THRUST WASHERS (12) PLANET GEARS (6)
ZG TRANSMISSION AND TRANSFER CASE 21 - 141
DISASSEMBLY AND ASSEMBLY (Continued)
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Assembl e l ow range gear, i nput gear thrust
washers, i nput gear and i nput gear retai ner (Fi g. 64).
(2) I nstal l l ow range gear snap ri ng (Fi g. 65).
(3) Lubri cate i nput gear and l ow range gears wi th
automati c transmi ssi on fl ui d.
(4) Start i nput gear shaft i nto front case beari ng.
(5) Press i nput gear shaft i nto front beari ng.
(6) I nstal l new i nput gear snap ri ng (Fi g. 66).
(7) Appl y 3 mm (1/8 i n.) wi de bead of Mopar gas-
ket maker or si l i cone adhesi ve seal er to seal surface
of front beari ng retai ner.
(8) I nstal l front beari ng retai ner (Fi g. 67). Ti ghten
retai ner bol ts to 16 ft. l bs. (21 Nm) torque.
Fig. 63 Differential Case Assembly
TOP CASE BOTTOM CASE CASE ALIGNMENT MARKS
Fig. 64 Low Range And Input Gear Assembly
THRUST WASHERS LOW RANGE GEAR INPUTGEAR RETAINER
Fig. 65 Install Low Range Gear Snap Ring
LOW RANGE GEAR SNAP RING
Fig. 66 Input Gear Snap Ring Installation
INPUT GEAR SNAP RING
21 - 142 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 68).
(2) I nstal l shi ft sector.
(3) I nstal l new pads on l ow range fork, i f neces-
sary, (Fi g. 69).
(4) Assembl e l ow range fork and hub (Fi g. 69).
(5) Posi ti on l ow range fork and hub i n case. Be
sure l ow range fork pi n i s engaged i n shi ft sector sl ot
(Fi g. 70).
Fig. 67 Installing Front Bearing Retainer
FRONT BEARING RETAINER
Fig. 68 Sector O-Ring And Bushing Installation
SECTOR BUSHING O-RING
Fig. 69 Assembling Low Range Fork And Hub
LOW RANGE FORK PADS HUB
Fig. 70 Positioning Low Range Fork
SHIFT SECTOR LOW RANGE FORK PIN SLOT
ZG TRANSMISSION AND TRANSFER CASE 21 - 143
DISASSEMBLY AND ASSEMBLY (Continued)
(6) I nstal l fi rst mai nshaft beari ng spacer on mai n-
shaft (Fi g. 71).
(7) I nstal l beari ng rol l ers on mai nshaft (Fi g. 71).
Coat bearing rollers with generous quantity of
petroleum jelly to hold them in place.
(8) I nstal l remai ni ng beari ng spacer on mai nshaft
(Fi g. 71). Do not di spl ace any beari ngs whi l e i nstal l -
i ng spacer.
(9) I nstal l di fferenti al (Fi g. 72). Do not displace
mainshaft bearings when installing differential.
(10) I nstal l di fferenti al snap-ri ng (Fi g. 73).
(11) I nstal l i ntermedi ate cl utch shaft (Fi g. 74).
Fig. 71 Installing Mainshaft Bearing Rollersand
Spacers
MAINSHAFT BEARING ROLL- ERS BEARING SPACERS
Fig. 72 Differential Installation
DIFFERENTIAL MAINSHAFT
Fig. 73 Installing Differential Snap-Ring
DIFFERENTIAL SNAP RING
Fig. 74 Installing Intermediate Clutch Shaft
INTERMEDIATE CLUTCH SHAFT
21 - 144 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(12) I nstal l cl utch shaft thrust washer (Fi g. 75).
(13) I nstal l cl utch shaft snap-ri ng (Fi g. 76).
(14) I nspect mode fork assembl y (Fi g. 77). Repl ace
pads and bushi ng i f necessary. Repl ace fork tube i f
bushi ngs i nsi de tube are worn or damaged. Al so
check spri ngs and sl i der bracket (Fi g. 77). Repl ace
worn, damaged components.
(15) I nstal l mode sl eeve i n mode fork (Fi g. 78).
Then i nstal l assembl ed sl eeve and fork on mai nshaft.
Be sure mode sl eeve spl i nes are engaged i n di fferen-
ti al spl i nes.
(16) I nstal l mode fork and mai nshaft assembl y i n
case (Fi g. 79). Rotate mai nshaft sl i ghtl y to engage
shaft wi th l ow range gears.
Fig. 75 Installing Clutch Shaft Thrust Washer
CLUTCH SHAFT THRUSTRING
Fig. 76 Installing Clutch Shaft Snap-Ring
SNAP RING INTERMEDIATE CLUTCH SHAFT
Fig. 77 Mode Fork Assembly Inspection
SLIDER MODE FORK BUSHING/SPRING TUBE PADS
Fig. 78 Installing Mode Fork And Sleeve
MAINSHAFT SLEEVE MODE FORK ASSEMBLY
ZG TRANSMISSION AND TRANSFER CASE 21 - 145
DISASSEMBLY AND ASSEMBLY (Continued)
(17) Rotate mode fork pi n i nto shi ft sector sl ot.
(18) I nstal l shi ft rai l (Fi g. 80). Be sure rail is
seated in both shift forks.
(19) Rotate shi ft sector to al i gn l ockpi n hol e i n l ow
range fork wi th access hol e i n case.
(20) I nsert an easy-out i n range fork l ockpi n to
hol d i t securel y for i nstal l ati on (Fi g. 81). Lockpin is
slightly tapered on one end. Insert tapered end
into fork and rail.
(21) I nsert l ockpi n through access hol e and i nto
shi ft fork (Fi g. 81). Then remove easy-out and seat
the pi n wi th pi n punch.
(22) I nstal l pl ug i n l ockpi n access hol e.
(23) I nstal l detent pl unger, detent spri ng and
detent pl ug i n case (Fi g. 82).
Fig. 79 Assembled Mainshaft And Mode
ForkInstallation
MAINSHAFT ASSEMBLY MODE FORK
Fig. 80 Shift Rail Installation
SHIFT RAIL MODE FORK
Fig. 81 Installing Low Range Fork Lockpin
LOW RANGE FORK LOCK PIN ACCESS HOLE EASY-OUT
Fig. 82 Detent Pin, Spring And Plug Installation
PLUNGER O-RING PLUG SPRING
21 - 146 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) I nstal l front output shaft (Fi g. 83).
(2) I nstal l dri ve chai n (Fi g. 83). Engage chai n wi th
front output shaft sprocket teeth.
(3) I nstal l dri ve sprocket (Fi g. 83). Engage dri ve
sprocket teeth wi th chai n. Then engage sprocket
spl i nes wi th mai nshaft spl i nes.
(4) I nstal l dri ve sprocket snap-ri ng (Fi g. 84).
OIL PUMP AND REAR CASE INSTALLATION
(1) I nsert oi l pi ckup tube i n oi l pump and attach
oi l screen and connector hose to pi ckup tube. Then
i nstal l assembl ed pump, tube and screen i n rear case
(Fi g. 85). Be sure screen i s seated i n case sl ot as
shown.
(2) I nstal l magnet i n front case pocket (Fi g. 86).
(3) Appl y 3 mm (1/8 i n.) wi de bead of Mopar gas-
ket maker or si l i cone adhesi ve seal er to seal surface
of front case.
(4) Al i gn and i nstal l rear case on front case. Be
sure case l ocati ng dowel s are i n pl ace and that mai n-
shaft spl i nes are engaged i n oi l pump i nner gear.
(5) I nstal l and ti ghten front case-to-rear case bol ts
to 41 Nm (30 ft. l bs.) torque. Be sure to install a
Fig. 83 Drive Chain And Sprocket Installation
FRONT OUTPUT SHAFT DRIVE CHAIN DRIVE SPROCKET
Fig. 84 Drive Sprocket Snap-Ring Installation
DRIVE SPROCKET DRIVE SPROCKET SNAP RING
Fig. 85 Oil Screen And Pickup Tube Installation
OIL PUMP OIL SCREEN CONNECTOR PICKUP TUBE
Fig. 86 Installing Case Magnet
MAGNET
ZG TRANSMISSION AND TRANSFER CASE 21 - 147
DISASSEMBLY AND ASSEMBLY (Continued)
washer under each bolt used at case dowel
locations.
REAR RETAINER INSTALLATION
(1) Remove rear beari ng i n retai ner usi ng I nstal l er
8128 and Handl e C-4171.
(2) I nstal l rear beari ng i n retai ner wi th Tool s
C-4171 and 5064 (Fi g. 87).
(3) I nstal l rear beari ng O.D. retai ni ng ri ng wi th
snap-ri ng pl i ers (Fi g. 88). Be sure retai ni ng ri ng i s
ful l y seated i n retai ner groove.
(4) Appl y bead of Mopar Seal er P/N 82300234, or
Locti te Ul tra Gray, to mati ng surface of rear
retai ner. Seal er bead shoul d be a maxi mum of 3/16
i n.
(5) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 2027 Nm (1520 ft. l bs.) torque.
(6) I nstal l rear beari ng I .D. retai ni ng ri ng and
spacer on output shaft.
(7) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(8) Sl i de seal onto Seal Protector 6992 (Fi g. 89).
Sl i de seal protector and seal onto output shaft.
(9) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th i nstal l er
C-4076-B and handl e MD-998323 (Fi g. 90).
(10) I nstal l rear sl i nger wi th i nstal l er C-4076-A
and handl e MD-998323 (Fi g. 90).
(11) I nstal l boot on output shaft sl i nger and cri mp
retai ni ng cl amp wi th tool C-4975-A (Fi g. 91).
FRONT YOKE AND SWITCH INSTALLATION
(1) I nstal l i ndi cator swi tch i n front case. Ti ghten
swi tch to 2034 Nm (1525 ft. l bs.) torque.
(2) Lubri cate yoke hub wi th transmi ssi on fl ui d and
i nstal l yoke on front shaft.
(3) I nstal l new seal washer on front shaft.
Fig. 87 Installing Rear Bearing In Retainer
SPECIAL TOOL C-4171 SPECIAL TOOL 5064 REAR RETAINER
Fig. 88 Rear Bearing Retaining Ring Installation
REAR BEARING O.D. RETAINING RING SNAP RING PLIERS
Fig. 89 Output Shaft Seal and Protector
OUTPUT SHAFT SEAL SPECIAL TOOL 6992 TRANSFER CASE
Fig. 90 Rear Seal Installation
SPECIAL TOOL C-4076B SPECIAL TOOL MD998323 TRANSFER CASE
21 - 148 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(4) I nstal l yoke on front shaft. Secure yoke wi th
new nut.
CLEANING AND INSPECTION
NV242 TRANSFER CASE
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and al l
purpose cl eaner. Use compressed ai r to remove sol -
vent resi due from oi l feed passages i n the case
hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
MAINSHAFT/SPROCKET/HUB INSPECTION
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket. Mi nor ni cks and scratches can
be smoothed wi th an oi l stone, however, repl ace any
part i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320400 gri t emery cl oth but do
not try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 92). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 93). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320400 gri t emery cl oth.
I nspect the shi ft fork wear pads. The mode fork
pads are servi ceabl e and can be repl aced i f necessary.
The range fork pads are al so servi ceabl e.
Fig. 92 Input Gear And Carrier Components
PLANETARY CARRIER REAR THRUST WASHER FRONT THRUST WASHER CARRIER LOCK RING CARRIER LOCK RETAINING RING INPUT GEAR
Fig. 91 Slinger Boot Installation
SPECIAL TOOL C-4975A SLINGER BOOT CLAMP
ZG TRANSMISSION AND TRANSFER CASE 21 - 149
DISASSEMBLY AND ASSEMBLY (Continued)
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER/BEARING/ SEAL/SLINGER/
BOOT
I nspect the retai ner components (Fi g. 94). Repl ace
the beari ng i f rough or noi sy. Check the retai ner for
cracks or wear i n the beari ng bore. Cl ean the
retai ner seal i ng surfaces wi th a scraper and al l pur-
pose cl eaner. Thi s wi l l ensure proper adhesi on of the
seal er duri ng reassembl y.
Repl ace the sl i nger and seal outri ght; do not reuse
ei ther part.
I nspect the retai ni ng ri ngs and washers. Repl ace
any part i f di storted, bent, or broken. Reuse i s not
recommended. Al so repl ace the boot i f cut or torn.
Repl ace the boot band cl amps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces of the
yoke sl i nger (Fi g. 95). Thi s surface must be cl ean and
smooth to ensure proper seal l i fe. Repl ace the yoke
nut and seal washer as nei ther part shoul d be
reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320400 gri t emery
to smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
repl ace the chai n i f stretched, di storted, or i f any of
the l i nks bi nd. Repl ace the beari ngs i f rough, or
noi sy.
Fig. 94 Rear Retainer Components
REAR RETAINER REAR BEARING I.D. RETAINING RING REAR SEAL REAR SLINGER LOCATINGWASHER BOOT BAND CLAMPS REARSLINGER REAR SLINGER LOCATING RING REAR BEARING O.D. RETAINING RING REAR BEARING
Fig. 93 Shift forks
RANGE FORK MODE FORK AND RAIL MODE SPRING
21 - 150 TRANSMISSION AND TRANSFER CASE ZG
CLEANING AND INSPECTION (Continued)
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 96).
FRONT-REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Cl ean the seal i ng surfaces wi th a scraper and al l
purpose cl eaner. Thi s wi l l ensure proper seal er adhe-
si on at assembl y. Repl ace the i nput retai ner seal ; do
not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai nl ess
steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ADJ USTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shi ft transfer case i nto 4L posi ti on.
(2) Rai se vehi cl e.
(3) Loosen l ock bol t on adjusti ng trunni on (Fi g.
97).
(4) Be sure l i nkage rod sl i des freel y i n trunni on.
Cl ean rod and appl y spray l ube i f necessary.
(5) Veri fy that transfer case range l ever i s ful l y
engaged i n 4L posi ti on.
(6) Ti ghten adjusti ng trunni on l ock bol t.
(7) Lower vehi cl e.
Fig. 95 Seal Contact Surface Of Yoke Slinger
FRONT SLINGER (PARK OF YOKE) SEAL CONTACT SUR- FACE MUST BE CLEAN AND SMOOTH
Fig. 96 Low Range Annulus Gear
FRONT CASE LOW RANGE ANNU- LUS GEAR
Fig. 97 Shift Linkage
TRANSFER CASE RANGE SHAFT
SEAL
TRANSFER CASE SHIFT LEVER ASSEMBLY FLOORPAN TRUNNION LOCK BOLT SHIFT ROD ADJUSTING TRUNNION TORQUE SHAFT BRACKET RANGE LEVER TORQUE SHAFT ROD TORQUE SHAFT LINKAGE BRACKET
ZG TRANSMISSION AND TRANSFER CASE 21 - 151
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Detent . . . . . . . . . . 1624 Nm (1218 ft. l bs.)
Bol t, Di ff. Case . . . . . . . . 1727 Nm (1524 ft. l bs.)
Pl ug, Drai n/Fi l l . . . . . . . . 4045 Nm (3040 ft. l bs.)
Bol t, Front Brg. Retai ner . 1627 Nm (1220 ft. l bs.)
Bol t, Case Hal f . . . . . . . . 3546 Nm (2634 ft. l bs.)
Nut, Front Yoke . . . . . 122176 Nm (90130 ft. l bs.)
Screw, Oi l Pump . . . . . . 1.21.8 Nm (1215 i n. l bs.)
Nut, Range Lever . . . . . . 2734 Nm (2025 ft. l bs.)
Bol t, Rear Retai ner . . . . . 3546 Nm (2634 ft. l bs.)
Nuts, Mounti ng . . . . . . . . 3547 Nm (2635 ft. l bs.)
Bol ts, U-Joi nt . . . . . . . . . . . . . . . 19 Nm (17 ft. l bs.)
SPECIAL TOOLS
SPECIAL TOOLS NV242
InstallerC-4076-B
Handle, UniversalC-4171
RemoverC-4210
Puller, SlingerMD-998056A
InstallerMD-998323
Installer, Bearing5064
21 - 152 TRANSMISSION AND TRANSFER CASE ZG
Installer8128
Installer5066
Installer6952-A
RemoverL-4454
Cup8148
Seal Protector6992
Installer, Input Gear Bearing7829-A
Installer, Seal7884
ZG TRANSMISSION AND TRANSFER CASE 21 - 153
SPECIAL TOOLS (Continued)
Installer, Pump Housing Seal7888
Installer, Bearing8033-A
Installer, Boot ClampC-4975-A
21 - 154 TRANSMISSION AND TRANSFER CASE ZG
SPECIAL TOOLS (Continued)
NV249 TRANSFER CASE
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . 155
RECOMMENDED LUBRICANT AND FILL LEVEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
TRANSFER CASE IDENTIFICATION . . . . . . . . 155
DIAGNOSIS AND TESTING
NV249 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 156
REMOVAL AND INSTALLATION
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . 160
REAR RETAINER BUSHING AND SEAL . . . . . 160
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . 158
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . 158
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . 157
DISASSEMBLY AND ASSEMBLY
NV249 TRANSFER CASE . . . . . . . . . . . . . . . . 161
CLEANING AND INSPECTION
NV249 COMPONENTS . . . . . . . . . . . . . . . . . . 175
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . 176
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
SPECIAL TOOLS
NV249 TRANSFER CASE . . . . . . . . . . . . . . . . 178
GENERAL INFORMATION
GENERAL INFORMATION
The NV249 (Fi g. 1) i s a ful l ti me 4-wheel dri ve
transfer case wi th two operati ng ranges and a neu-
tral posi ti on.
Operati ng ranges are 4-hi gh and 4-l ow. The 4-l ow
range i s used for extra pul l i ng power i n off-road si t-
uati ons.
Engi ne torque i s di stri buted to the front and rear
axl es through a vi scous coupl i ng. The NV249 l ow
range i s provi ded by a gear reducti on system for
i ncreased l ow speed, off-road torque capabi l i ty.
Transfer case operati ng ranges are sel ected wi th a
fl oor mounted shi ft l ever. The shi ft l ever i s connected
to the transfer case range l ever by an adjustabl e
l i nkage rod. Range posi ti ons are marked on the
shi fter bezel pl ate.
TRANSFER CASE IDENTIFICATION
A ci rcul ar I .D. tag i s attached to the rear case of
each NV249 transfer case (Fi g. 2). The tag provi des
the transfer case model number, assembl y number,
seri al number and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
RECOMMENDED LUBRICANT AND FILL LEVEL
Mopar Dexron I I , or ATF Pl us are the onl y l ubri -
cants recommended for the NV249 transfer case.
Approxi mate fl ui d refi l l capaci ty i s approxi matel y
1.18 l i ters (2.50 pi nts).
The fi l l and drai n pl ugs are both i n the rear case.
Correct fi l l l evel i s to the bottom edge of the fi l l pl ug
hol e. Be sure that the vehi cl e i s l evel to ensure an
accurate fl ui d l evel check.
Fig. 1 NV249 Transfer Case
Fig. 2 Transfer Case I.D. Tag
I.D. TAG FILL PLUG DRAIN PLUG
ZG TRANSMISSION AND TRANSFER CASE 21 - 155
DIAGNOSIS AND TESTING
NV249 DIAGNOSIS
Condition Possible Cause Correction
TRANSFER CASE DIFFICULT TO
SHIFT OR WILL NOT SHIFT INTO
DESIRED RANGE
(a) Vehicle speed too great to
permit shifting.
(a) Stop vehicle and shift into
desired range. Or reduce speed to
3-4 km/h (2-3 mph) before
attempting to shift.
(b) If vehicle was operated for
extended period in 4H mode on dry
paved surface, driveline torque load
may cause difficulty.
(b) Stop vehicle, shift transmission
to neutral, shift transfer case to 2H
mode and operate vehicle on 2H on
dry paved surface.
(c) Transfer case external shift
linkage binding.
(c) Lubricate, repair or replace
linkage, or tighten loose
components as necessary.
(d) Insufficient or incorrect lubricant. (d) Drain and refill to edge of fill
hole with MOPAR ATF PLUS (Type
7176) or DEXRON II Automatic
Transmission Fluid.
(e) Internal components binding,
worn or damaged.
(e) Disassemble unit and replace
worn or damaged components as
necessary.
TRANSFER CASE NOISY IN ALL
DRIVE MODES
(a) Insufficient or incorrect lubricant. (a) Drain and refill to edge of fill
hole with MOPAR ATF PLUS (Type
7176) or DEXRON II Automatic
Transmission Fluid. Check for leaks
and repair if necessary. If unit is
still noisy after drain and refill,
disassembly and inspection may
be required to locate source of
noise.
NOISY IN-OR JUMPS OUT OF
FOUR-WHEEL-DRIVE LOW
RANGE
(a) Transfer case not completely
engaged in 4L position.
(a) Stop vehicle, shift transfer case
to Neutral, then shift back into 4L
position.
(b) Shift linkage loose or binding. (b) Tighten, lubricate, or repair
linkage as necessary.
(c) Range fork cracked, inserts
worn, or fork is binding on shift rail.
(c) Disassemble unit and repair as
necessary.
(d) Annulus gear or lockplate worn
or damaged.
(d) Disassemble unit and repair as
necessary.
LUBRICANT LEAKING FROM
OUTPUT SHAFT SEALS OR
FROM VENT
(a) Transfer case overfilled. (a) Drain to correct level.
(b) Vent closed or restricted. (b) Clear or replace vent if
necessary.
(c) Output shaft seals damaged or
installed correctly.
(c) Replace seals. Be sure seal lip
faces interior of case when installed.
Also be sure yoke seal surfaces are
not scored or nicked. Remove
scores and nicks with fine
sandpaper or replace yoke(s) if
necessary.
ABNORMAL TIRE WEAR (a) Extended operation on dry hard
surface (paved) roads in 4H range.
(a) Operate in 2H on hard surface
(paved) roads.
21 - 156 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(2) Rai se vehi cl e.
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
al i gnment reference.
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember, or ski d pl ate.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 3)
and i ndi cator swi tch harness, i f necessary.
(11) Support transfer case wi th transmi ssi on jack.
(12) Secure transfer case to jack wi th chai ns.
(13) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(2) Secure transfer case to jack wi th chai ns.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (26 ft. l bs.) torque (Fi g. 3).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch, i f necessary. Secure wi re harness to cl i ps
on transfer case.
(8) Al i gn and connect propel l er shafts. Ti ghten
shaft attachi ng bol ts to 19 Nm (170 i n. l bs.) torque.
(9) Fi l l transfer case wi th correct fl ui d. Refer to
Recommended Lubri cant And Fi l l Level secti on for
proper fl ui d and capaci ty.
(10) I nstal l rear crossmember, or ski d pl ate.
Ti ghten crossmember bol ts to 41 Nm (30 ft. l bs.)
torque.
(11) Remove transmi ssi on jack and support stand.
(12) Connect shi ft rod to transfer case range l ever.
(13) Adjust transfer case shi ft l i nkage.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
Fig. 3 Transfer Case Mounting
VENT TUBE TRANSFER CASE TRANSMISSION
ZG TRANSMISSION AND TRANSFER CASE 21 - 157
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(2) Rai se vehi cl e.
(3) Loosen adjusti ng trunni on l ocknut and sl i de
shi ft rod out of trunni on (Fi g. 4). I f rod l acks enough
travel to come out of trunni on, push trunni on out of
torque shaft.
(4) Lower vehi cl e.
(5) Remove consol e. Refer to Group 23, Body, for
proper procedures.
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. Refer to Group 23, Body, for
proper procedures.
(3) Rai se vehi cl e.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
(6) Lower vehi cl e and check transfer case shi ft
operati on.
SPEEDOMETER
REMOVAL
(1) Rai se vehi cl e.
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 5).
(4) Remove speed sensor and speedometer adapter
as an assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
Repl ace pi ni on i f chi pped, cracked, or worn.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 5).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
severel y corroded, or damaged.
Fig. 4 Shift Linkage
TORQUE
(2735 in. lbs.)
(97123 in. lbs.)
(72120 in. lbs.)
RIVNUT (4) SHIFT LEVER ASSEMBLY FLOORPAN TRUNNION LOCK BOLT SELECTOR ROD AND TRUN- NION SHIFT LEVER ROD TORQUE SHAFT FRAME BRACKET TORQUE SHAFT TRANSFER CASE SHIFT LEVER TORQUE SHAFT TRANSFER CASE BRACKET
21 - 158 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION AND INDEXING
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter (Fi g. 5), i f necessary.
(3) Lubri cate sensor and adapter O-ri ngs wi th
transmi ssi on fl ui d.
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 Nm
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 6).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 Nm (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel i f necessary.
ITEM TORQUE
A 2-3 Nm (15-27 in. lbs.)
B 10-12 Nm (90-110 in. lbs.)
Fig. 5 Speedometer Components
ITEM
TORQUE SENSOR O-RING SPEEDOMETER ADAPTER ADAPTER O-RING SPEEDOMETER PINION ADAPTER CLAMP VEHICLE SPEED SENSOR
Fig. 6 Location Of Index Numbers On
SpeedometerAdapter
SPEEDOMETER ADAPTER INDEX NUMBER LOCA- TION
ZG TRANSMISSION AND TRANSFER CASE 21 - 159
REMOVAL AND INSTALLATION (Continued)
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove front propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
7).
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 6952-A as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 8). Once seal i s started, conti nue tappi ng
seal i nto bore unti l i nstal l er tool seats agai nst case.
REAR RETAINER BUSHING AND SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove rear propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear retai ner seal .
(4) Usi ng Remover 6957, remove bushi ng from
rear retai ner (Fi g. 9).
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Posi ti on repl acement bushi ng i n rear retai ner
wi th fl ui d port i n bushi ng al i gned wi th sl ot i n
retai ner.
(3) Usi ng I nstal l er 8145, dri ve bushi ng i nto
retai ner unti l i nstal l er seats agai nst case (Fi g. 10).
(4) Usi ng I nstal l er C-3995-A, i nstal l seal i n rear
retai ner (Fi g. 11).
(5) I nstal l propel l er shaft.
(6) Veri fy proper fl ui d l evel .
(7) Lower vehi cl e.
Fig. 7 Remove Front Output Shaft Seal
OUTPUT SHAFTSEAL PRYBAR
Fig. 8 Front Output Seal Installation
INSTALLER 6952A TRANSFER CASE
Fig. 9 Rear Retainer Bushing Removal
REMOVER 6957 REAR RETAINER BUSHING
Fig. 10 Rear Retainer Bushing Install
INSTALLER 8145 REAR RETAINER BUSHING
21 - 160 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
DISASSEMBLY AND ASSEMBLY
NV249 TRANSFER CASE
DISASSEMBLY
Posi ti on transfer case on shal l ow drai n pan.
Remove drai n pl ug and drai n l ubri cant remai ni ng i n
case.
REAR RETAINER AND OIL PUMP REMOVAL
(1) Remove the speedometer adapter.
(2) Remove rear retai ner bol ts (Fi g. 12).
(3) Remove rear beari ng l ocati ng ri ng access cover
screws, cover and gasket (Fi g. 13).
(4) Loosen rear retai ner wi th pry tool to break
seal er bead. Pry onl y agai nst retai ner boss as shown
(Fi g. 14).
(5) Remove rear retai ner as fol l ows:
(a) Spread rear beari ng l ocati ng ri ng wi th snap
ri ng pl i ers (Fi g. 15).
(b) Then sl i de retai ner off mai nshaft and rear
beari ng (Fi g. 16).
(6) Remove speedometer dri ve gear (Fi g. 17).
Fig. 11 Install Rear Retainer Seal
SPECIAL TOOL C-4171 SPECIAL TOOL C-3995A
Fig. 12 Rear Retainer Bolt Removal
REAR RETAINER
Fig. 13 Locating Ring Access Cover And
GasketRemoval
REAR BEAR- ING LOCAT- ING RING ACCESS COVER AND GASKET
Fig. 14 Loosening Rear Retainer
RETAINER BOSS PRY TOOL
SEALER
BEAD
REAR RETAINER
Fig. 15 Disengaging Rear Bearing LocatingRing
REAR RETAINER PARALLEL JAW SNAP RING PLI- ERS
ZG TRANSMISSION AND TRANSFER CASE 21 - 161
(7) Remove rear beari ng snap-ri ng.
(8) Remove rear beari ng. Note posi ti on of beari ng
l ocati ng ri ng groove for assembl y reference.
(9) Di sengage oi l pi ckup tube from oi l pump and
remove oi l pump assembl y (Fi g. 18).
(10) Remove pi ck-up tube o-ri ng from oi l pump
(Fi g. 19), i f necessary. Do not di sassembl e the oi l
pump, i t i s not servi ceabl e.
VISCOUS COUPLER REMOVAL
(1) Remove oi l pump l ocati ng snap-ri ng and vi s-
cous coupl i ng snap-ri ng from mai nshaft (Fi g. 20).
(2) Remove vi scous coupl i ng from mai nshaft (Fi g.
20).
YOKE AND RANGE LEVER REMOVAL
(1) Remove transfer case i ndi cator swi tch.
(2) Remove front yoke nut as fol l ows:
(a) Move range l ever to 4L posi ti on.
(b) Remove nut wi th socket and i mpact wrench
(Fi g. 21).
(3) Remove yoke. I f yoke i s di ffi cul t to remove by
hand, remove i t wi th beari ng spl i tter, or wi th stan-
dard two jaw pul l er (Fi g. 22). Be sure pul l er tool i s
posi ti oned on yoke and not on sl i nger as sl i nger wi l l
be damaged.
Fig. 16 Rear Retainer Removal
REAR CASE REAR RETAINER
Fig. 17 Speedometer Drive Gear Removal
MAINSHAFT SPEEDOMETER DRIVE GEAR
Fig. 18 Rear Bearing and Oil Pump Removal
OIL PUMP TUBE O-RING OIL PICKUP TUBE
Fig. 19 Pick-up Tube O-ring Location
OIL PUMP O-RING
Fig. 20 Viscous Coupling Removal
TRANSFERCASE VISCOUS COU- PLING MAINSHAFT SNAP RINGS
21 - 162 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(5) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft (Fi g. 23).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Support transfer case so rear case i s faci ng
upward.
(2) Remove bol ts hol di ng front case to rear case. The
case al i gnment bol t requi re fl at washers (Fi g. 24).
(3) Loosen rear case wi th fl at bl ade screwdri ver to
break seal er bead. I nsert screwdri ver bl ade onl y i nto
notches provi ded at each end of case (Fi g. 25).
(4) Remove rear case (Fi g. 26).
Fig. 21 Yoke Nut Removal
IMPACT WRENCH SOCKET YOKE
Fig. 22 Yoke Removal
PULLERTOOL YOKE
Fig. 23 Range Lever Removal
RANGE LEVER SECTORSHAFT
Fig. 24 Rear Case Alignment Bolt Locations
ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 25 Loosening Rear Case
REAR CASE PRY TOOL (IN CASE SLOT) FRONT CASE
Fig. 26 Rear Case Removal
REAR HOUSING MAINSHAFT TRANSFER CASE
ZG TRANSMISSION AND TRANSFER CASE 21 - 163
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Remove oi l pi ckup tube from rear case (Fi g. 27).
(6) Remove dri ve gear snap-ri ng (Fi g. 28).
(7) Di sengage dri ve gear (Fi g. 28). Pry gear
upward and off mai nshaft as shown.
(8) Remove front output shaft, dri ve chai n and
dri ve gear as assembl y (Fi g. 28).
SHIFT FORKS AND MAINSHAFT REMOVAL
(1) Remove detent pl ug, O-ri ng, detent spri ng and
detent pl unger (Fi g. 29).
(2) Remove mai nshaft from cl utch sl eeve and i nput
gear pi l ot beari ng.
(3) Rotate shi ft sector so sector teeth face upward
(Fi g. 30).
(4) Remove range fork, rai l and cl utch sl eeve as
assembl y (Fi g. 31). Li ft shi ft rai l upward, rotate fork
out of shi ft sector and remove assembl y.
(5) Remove shi ft sector. Rotate and ti l t sector as
needed to remove i t (Fi g. 32).
(6) Remove shi ft sector bushi ng and O-ri ng (Fi g.
33).
Fig. 27 Oil Pickup Tube Removal
OIL PICKUP TUBE
Fig. 28 Front Output Shaft, Drive Gear AndChain
Removal
REAR HOUSING OUTPUT SHAFT AND SPROCKET MAINSHAFT SPROCKET SNAP RING DRIVE CHAIN
Fig. 29 Detent Plug, Spring And Plunger Removal
DETENT PLUG DETENT SPRING DETENT PLUNGER PLUGO-RING
Fig. 30 Rotating Shift Sector
SHIFT SECTOR (ROTATE SO TEETH FACE UPWARD)
Fig. 31 Range Fork And Clutch Sleeve Removal
RANGE FORK AND RAIL
CLUTCH
SLEEVE
21 - 164 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
INPUT GEAR/LOW RANGE ASSEMBLY REMOVAL
(1) Turn front case on si de so front beari ng
retai ner i s accessi bl e.
(2) Remove front beari ng retai ner bol ts (Fi g. 34).
(3) Remove front beari ng retai ner as fol l ows:
(a) Loosen retai ner wi th fl at bl ade screwdri ver
to break seal er bead. To avoid damaging case
and retainer, position screwdriver blade only
in slots provided in retainer (Fig. 35).
(b) Then remove retai ner from case and gear.
(4) Remove snap-ri ng that retai ns i nput gear shaft
i n front beari ng (Fi g. 36).
(5) Remove i nput and l ow range gear assembl y
(Fi g. 37).
(6) Remove oi l seal s from fol l owi ng components:
front beari ng retai ner.
rear retai ner.
case hal ves.
Fig. 32 Shift Sector Removal
SHIFT SEC- TOR
Fig. 33 Sector Bushing And O-Ring Removal
SHIFT SEC- TOR BUSHING O-RING
Fig. 34 Front Bearing Retainer Bolt Removal
FRONT BEARING RETAINER
Fig. 35 Front Bearing Retainer Removal
FRONT BEARING RETAINERRETAINER NOTCH FLAT BLADE SCREW- DRIVER
Fig. 36 Input Gear Snap-Ring Removal
INPUT GEAR SNAPRING
ZG TRANSMISSION AND TRANSFER CASE 21 - 165
DISASSEMBLY AND ASSEMBLY (Continued)
INPUT AND LOW RANGE GEAR DISASSEMBLY
(1) Remove snap-ri ng that retai ns i nput gear i n
l ow range gear (Fi g. 38).
(2) Remove retai ner (Fi g. 39).
(3) Remove front tabbed thrust washer (Fi g. 40).
(4) Remove i nput gear (Fi g. 41).
(5) Remove rear tabbed thrust washer from l ow
range gear (Fi g. 42).
ASSEMBLY
Lubri cate transfer case components wi th Mopar
Dexron I I automati c transmi ssi on fl ui d or petrol eum
jel l y (where i ndi cated) duri ng assembl y.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
Fig. 37 Input And Low Range Gear
AssemblyRemoval
INPUT AND LOW RANGE GEAR ASSEMBLY
Fig. 38 Input Gear Snap-Ring Removal
INPUT GEAR SNAP RING
Fig. 39 Input Gear Retainer Removal
INPUT GEAR LOW RANGE GEAR RETAINER
Fig. 40 Front Tabbed Thrust Washer Removal
FRONT TABBED THRUST WASHER
Fig. 41 Input Gear Removal
INPUT GEAR LOW RANGEGEAR
21 - 166 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
BEARING AND SEAL INSTALLATION
(1) Remove front output shaft seal from front case
wi th pry tool (Fi g. 43).
(2) Remove snap-ri ng that retai ns front output
shaft beari ng i n front case (Fi g. 44).
(3) Usi ng tool 6953, remove beari ng from front
case (Fi g. 45).
(4) Usi ng tool 6953, i nstal l new beari ng.
(5) I nstal l snap-ri ng to hol d beari ng i nto case.
(6) I nstal l new front output seal i n front case wi th
I nstal l er Tool 6952-A as fol l ows:
(a) Pl ace new seal on tool . Garter spring on
seal goes toward interior of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 46). Once seal i s started, conti nue tap-
pi ng seal i nto bore unti l i nstal l er tool bottoms
agai nst case.
(7) Remove the output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 47).
Fig. 42 Rear Tabbed Thrust Washer Removal
LOW RANGE GEAR REAR TABBED THRUST WASHER
Fig. 43 Remove Front Output Shaft Seal
OUTPUT SHAFTSEAL PRYBAR
Fig. 44 Output Shaft Front Bearing Snap-RingRemoval
FRONT CASE
OUTPUT SHAFT FRONT BEARING BEARING SNAP RING
Fig. 45 Remove Output Shaft Front Bearing
HANDLE C-4171 REMOVER/INSTALLER 6953
Fig. 46 Front Output Seal Installation
INSTALLER 6952A TRANSFER CASE
ZG TRANSMISSION AND TRANSFER CASE 21 - 167
DISASSEMBLY AND ASSEMBLY (Continued)
(8) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 48). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig.
49).
(9) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng from i nsi de the annul us
gear openi ng i n the case. (Fi g. 50).
(10) I nstal l l ocati ng ri ng on new beari ng.
(11) Posi ti on case so forward end i s faci ng upward.
(12) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng i nto case. The beari ng
l ocati ng ri ng must be ful l y seated agai nst case sur-
face (Fi g. 51).
Fig. 47 Output Shaft Rear Bearing Removal
REAR CASE SPECIAL TOOL L-44541 AND L-44543 SPECIAL TOOL 8148
Fig. 48 Output Shaft Rear Bearing Installation
HANDLE C-4171 OUTPUT SHAFT INNER BEARING INSTALLER 5066
Fig. 49 Output Shaft Rear Bearing InstallationDepth
BEARING (SEATED) AT LOWER EDGE OF CHAMFER CHAMFER
Fig. 50 Input Shaft Bearing Removal
SPECIAL TOOL C-4171SPECIAL TOOL C-4210
21 - 168 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(13) Remove i nput gear pi l ot beari ng by i nserti ng
a sui tabl y si zed dri ft i nto the spl i ned end of the i nput
gear and dri vi ng the beari ng out wi th the dri ft and a
hammer (Fi g. 52).
(14) I nstal l new pi l ot beari ng wi th I nstal l er 8128
and Handl e C-4171 (Fi g. 53).
(15) Remove front beari ng retai ner seal wi th sui t-
abl e pry tool .
(16) I nstal l new front beari ng retai ner wi th
I nstal l er 7884 (Fi g. 54).
Fig. 51 Seating Input Shaft Bearing
SNAP RING INPUT SHAFT BEARING
Fig. 52 Remove Input Gear Pilot Bearing
DRIFT INPUT GEAR
Fig. 53 Install Input Gear Pilot Bearing
HANDLE C-4171 INSTALLER 8128 INPUT GEAR
Fig. 54 Install Front Bearing Retainer Seal
FRONT BEARING RETAINER SPECIAL TOOL 7884
ZG TRANSMISSION AND TRANSFER CASE 21 - 169
DISASSEMBLY AND ASSEMBLY (Continued)
INPUT AND LOW RANGE GEAR ASSEMBLY
(1) Lubri cate gears and thrust washers (Fi g. 55)
wi th recommended transmi ssi on fl ui d.
(2) I nstal l fi rst thrust washer i n l ow range gear
(Fi g. 55). Be sure washer tabs are properl y al i gned i n
gear notches.
(3) I nstal l i nput gear i n l ow range gear. Be sure
i nput gear i s ful l y seated.
(4) I nstal l remai ni ng thrust washer i n l ow range
gear and on top of i nput gear. Be sure washer tabs
are properl y al i gned i n gear notches.
(5) I nstal l retai ner on i nput gear and i nstal l snap-
ri ng.
INPUT GEAR/LOW RANGE INSTALLATION
(1) Al i gn and i nstal l l ow range/i nput gear assem-
bl y i n front case (Fi g. 56). Be sure l ow range gear
pi ni ons are engaged i n annul us gear and that i nput
gear shaft i s ful l y seated i n front beari ng.
(2) I nstal l snap-ri ng to hol d i nput/l ow range gear
i nto front beari ng (Fi g. 57).
(3) Cl ean gasket seal er resi due from retai ner and
i nspect retai ner for cracks or other damage.
(4) Appl y a 3 mm (1/8 i n.) bead of Mopar gasket
maker or si l i cone adhesi ve to seal i ng surface of
retai ner.
(5) Al i gn cavi ty i n seal retai ner wi th fl ui d return
hol e i n front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying Mopar gas-
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.
(6) I nstal l bol ts to hol d retai ner to transfer case
(Fi g. 58). Ti ghten to 21 Nm (16 ft. l bs.) of torque.
Fig. 55 Input/Low Range Gear Components
SNAP RING RETAINER PLATE INPUT GEAR LOW RANGE GEAR THRUST WASHERS
Fig. 56 Input/Low Range Gear Installation
ANNULUS GEAR
INPUT/LOW RANGE
GEAR
Fig. 57 Install Snap-Ring
INPUT GEAR SNAPRING
Fig. 58 Install Front Bearing Retainer
FRONT BEARING RETAINER
21 - 170 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 59).
(2) I nstal l shi ft sector (Fi g. 60).
(3) I nstal l new pads on range fork (Fi g. 61), i f nec-
essary.
(4) I nstal l cl utch sl eeve i n range fork (Fi g. 61).
(5) I nstal l assembl ed range fork and cl utch sl eeve
(Fi g. 62).
(6) I nsert range fork pi n i n sector. Then rotate sec-
tor and seat cl utch gear i n l ow range gear.
(7) Veri fy that range fork rai l i s seated i n case
bushi ng and that cl utch sl eeve i s properl y engaged i n
l ow range gear.
(8) Rotate sector to Neutral posi ti on.
(9) I nstal l new O-ri ng on detent pl ug (Fi g. 63).
(10) Lubri cate detent pl unger wi th transmi ssi on
fl ui d or l i ght coat of petrol eum jel l y.
(11) I nstal l detent pl unger, spri ng and pl ug (Fi g.
63).
(12) Veri fy that pl unger i s properl y engaged i n sec-
tor.
(13) I nsert mai nshaft i nto i nput gear pi l ot beari ng.
Fig. 59 Sector O-Ring And Bushing Installation
SECTOR BUSHING O-RING
Fig. 60 Shift Sector Installation
SHIFT SEC- TOR
Fig. 61 Assembling Range Fork And ClutchSleeve
RANGE FORK AND RAIL RANGE FORK PADS CLUTCH SLEEVE
Fig. 62 Range Fork And Clutch Sleeve Installation
RANGE FORK AND RAIL CLUTCHSLEEVE LOW RANGE GEAR
ZG TRANSMISSION AND TRANSFER CASE 21 - 171
DISASSEMBLY AND ASSEMBLY (Continued)
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) Lubri cate front output shaft-sprocket assembl y,
dri ve chai n and dri ve sprocket wi th transmi ssi on
fl ui d.
(2) Assembl e dri ve chai n, dri ve sprocket and front
output shaft (Fi g. 64).
(3) Start dri ve sprocket on mai nshaft.
(4) Gui de front shaft i nto beari ng and dri ve
sprocket onto mai nshaft dri ve gear (Fi g. 64).
(5) I nstal l dri ve sprocket snap-ri ng (Fi g. 65).
(6) Cl ean seal i ng fl anges of front case and rear
case wi th a wax and grease remover.
(7) Appl y 3 mm (1/8 i n.) wi de bead of Mopar gas-
ket maker or si l i cone adhesi ve seal er to mounti ng
fl ange of front case. Work seal er bead around bol t
hol es as shown (Fi g. 66).
(8) I nstal l oi l pi ckup tube i n rear case. Be sure
tube i s seated i n case notch as shown (Fi g. 67).
(9) I nstal l magnet i n front case pocket (Fi g. 68).
(10) Al i gn and i nstal l rear case on front case (Fi g.
69).
(11) Veri fy that oi l pi ckup tube i s sti l l seated i n
case notch and tube end i s poi nted toward mai nshaft
(Fi g. 70).
(12) I nstal l case attachi ng bol ts. Al i gnment bol ts
at each end of case are onl y ones requi ri ng washers
(Fi g. 71).
(13) Ti ghten case bol ts to 27-34 Nm (20-25 ft. l bs.)
torque.
YOKE AND RANGE LEVER INSTALLATION
(1) I nstal l i ndi cator swi tch i n front case. Ti ghten
swi tch to 2034 Nm (1525 ft. l bs.) torque.
Fig. 63 Shift Detent Components
DETENT PLUG DETENT SPRING DETENT PLUNGER PLUGO-RING
Fig. 64 Installing Drive Chain, Front OutputShaft
And Drive Sprocket
FRONT OUTPUT SHAFT DRIVE CHAIN MAINSHAFT DRIVE SPROCKET
Fig. 65 Installing Drive Sprocket Snap-Ring
MAINSHAFT DRIVE SPROCKET SNAP RING PLIERS DRIVE SPROCKET SNAP RING
Fig. 66 Applying Sealer To Front Case Flange
FRONT
CASE
FLANGE
SEALER BEAD
21 - 172 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
(2) I nstal l range l ever, washer and l ocknut on sec-
tor shaft (Fi g. 72). Ti ghten l ocknut to 27-34 Nm
(20-25 ft. l bs.) torque.
(3) I nstal l new seal washer on front output shaft
(Fi g. 74).
(4) Lubri cate yoke hub wi th transmi ssi on fl ui d and
i nstal l yoke on front shaft.
(5) I nstal l new seal washer on front shaft.
(6) I nstal l yoke and new yoke nut on front output
shaft (Fi g. 73).
Fig. 67 Oil Pickup Tube Installation
CASE NOTCH
OIL PICKUP TUBE ASSEMBLY CASE SLOT
Fig. 68 Installing Case Magnet
MAGNET
Fig. 69 Rear Case Installation
REARCASE FRONT CASE
Fig. 70 Checking Position Of Oil Pickup Tube
TUBE O-RING CORRECT PICKUP TUBE POSITION
Fig. 71 Alignment Bolt Location
ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 72 Range Lever Installation
RANGE LEVER WASHER LOCKNUT
ZG TRANSMISSION AND TRANSFER CASE 21 - 173
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Ti ghten yoke nut to 122-176 Nm (90-130 ft.
l bs.) torque. Use Tool C-3281, or si mi l ar tool to hol d
yoke whi l e ti ghteni ng yoke nut.
VISCOUS COUPLER
(1) I nstal l coupl i ng on mai nshaft (Fi g. 75).
(2) I nstal l coupl i ng retai ni ng snap-ri ng fi rst (Fi g.
75). Be sure snap ri ng i s ful l y seated before proceed-
i ng.
(3) I nstal l oi l pump l ocati ng snap-ri ng on mai n-
shaft (Fi g. 75).
REAR RETAINER AND OIL PUMP INSTALLATION
(1) I nstal l new O-ri ng on fl anged end of oi l pi ckup
tube.
(2) I nstal l oi l pump (Fi g. 76).
(3) I nsert oi l pi ckup tube i n pump (Fi g. 77).
(4) I nstal l rear beari ng on mai nshaft (Fi g. 77).
Locati ng ri ng groove i n beari ng goes toward end of
mai nshaft.
(5) I nstal l rear beari ng retai ni ng snap-ri ng (Fi g.
78).
(6) I nstal l speedometer dri ve gear (Fi g. 79).
(7) I nstal l rear beari ng l ocati ng ri ng i n rear
retai ner, i f ri ng was removed duri ng overhaul .
(8) Appl y 3 mm (1/8 i n.) wi de bead of Mopar gas-
ket maker or si l i cone adhesi ve seal er to mounti ng
surface of rear retai ner. Al l ow seal er to set-up
sl i ghtl y before proceedi ng.
(9) Sl i de rear retai ner onto mai nshaft (Fi g. 80).
(10) Spread rear beari ng l ocati ng ri ng and sl i de
rear retai ner i nto pl ace on rear case (Fi g. 81).
(11) I nstal l and ti ghten rear retai ner bol ts to 27-34
Nm (20-25 ft. l bs.).
(12) I nstal l l ocati ng ri ng access cover and gasket
(Fi g. 82). Ti ghten pl ate attachi ng screws to 10 Nm
(85 i n. l bs.) torque.
Fig. 73 Output Shaft Yoke Installation
OUTPUT SHAFT YOKE YOKE NUT
Fig. 74 Yoke Seal Washer Installation
YOKE SEAL WASHER
Fig. 75 Viscous Coupling And Oil Pump Snap-
RingInstallation
OIL PUMP LOCAT- ING RING VISCOUS COUPLING SNAP RING
Fig. 76 Installing Oil Pump
OIL PUMP TUBE O-RING OIL PICKUP TUBE
Fig. 77 Rear Bearing Installation
REAR BEARING
21 - 174 TRANSMISSION AND TRANSFER CASE ZG
DISASSEMBLY AND ASSEMBLY (Continued)
FINAL ASSEMBLY
(1) I nstal l drai n pl ug. Ti ghten pl ug to 41-54 Nm
(30-40 ft. l bs.) torque.
(2) Level transfer case and fi l l i t wi th Mopar
Dexron I I automati c transmi ssi on fl ui d. Correct fi l l
l evel i s to bottom edge of fi l l pl ug hol e.
(3) I nstal l and ti ghten fi l l pl ug to 41-54 Nm
(30-40 ft. l bs.) torque.
CLEANING AND INSPECTION
NV249 COMPONENTS
GENERAL
Cl ean the transfer case components wi th parts
cl eani ng sol vent. Fl ush the oi l passages i n the cases
and dri vetrai n components wi th sol vent. Thi s wi l l
hel p remove di rt and parti cl es from these passages.
Dry the transfer case components wi th compressed
ai r or al l ow them to ai r dry on cl ean shop towel s.
Appl y compressed ai r through al l oi l passages i n
the cases and gear components to cl ear them of any
resi due.
MAINSHAFT
Exami ne the mai nshaft components careful l y for
evi dence of wear or damage.
Repl ace the thrust washers i f worn or damaged.
Repl ace the mai nshaft and sprocket gears i f the
teeth or gear bores are worn or damaged.
Repl ace the mai nshaft beari ngs i f worn, fl at spot-
ted, bri nel l ed, or damaged i n any way.
Repl ace the mai nshaft i f i t exhi bi ts wear or dam-
age to the beari ng surfaces, spl i nes or gear teeth.
Fig. 78 Rear Bearing Snap-Ring Installation
REAR BEAR- ING SNAP RING PLIERS SNAP RING
Fig. 79 Speedometer Drive Gear Installation
MAINSHAFT SPEEDOMETER DRIVE GEAR
Fig. 80 Rear Retainer Installation
REAR CASE REAR RETAINER
Fig. 81 Engaging Rear Bearing Locating Ring
REAR RETAINER PARALLEL JAW SNAP RING PLI- ERS
Fig. 82 Installing Locating Ring Access CoverAnd
Gasket
REAR BEAR- ING LOCAT- ING RING ACCESS COVER AND GASKET
ZG TRANSMISSION AND TRANSFER CASE 21 - 175
DISASSEMBLY AND ASSEMBLY (Continued)
INPUT AND LOW RANGE GEARS
I nspect the l ow range gear pi ni ons and pi ni on pi ns.
Repl ace the l ow range gear i f any of the pi ns or pi n-
i ons are worn or damaged.
I nspect the thrust washers, retai ner, and snap-
ri ng. Repl ace the snap-ri ng i f bent, or di storted.
Repl ace the thrust washers and retai ner i f worn,
cracked or damaged i n any way.
Exami ne the i nput gear careful l y. Be sure the gear
teeth and beari ng surfaces are i n good condi ti on.
Repl ace the gear i f wear or damage i s evi dent.
Check the i nput gear pi l ot beari ng. Rotate the
beari ng and check for roughness or noi se. Al so check
beari ng posi ti on i n the bore. The beari ng shoul d be
recessed approxi matel y 2.5 mm (0.100 i n.) bel ow the
top edge of the bore. The beari ng shoul d not be
seated at the bottom of the bore. Repl ace the beari ng
i f worn, or roughness i s evi dent. Repl ace both the
gear and beari ng i f the beari ng i s a l oose fi t i n the
bore.
GEAR CASE AND RETAINERS
Exami ne both case hal ves and retai ners careful l y.
Repl ace any retai ner or case hal f i f wear, cracks, or
other damage i s evi dent.
Check condi ti on of the l ow range annul us gear and
the shi ft rai l bushi ng i n the front case (Fi g. 83). The
l ow range annul us gear i s not a servi ceabl e part.
Repl ace the gear and case as an assembl y i f the gear
i s l oose, worn, or damaged. The shi ft rai l bushi ng i s
a servi ceabl e part and can be repl aced i f necessary.
Check the bushi ng i n the rear retai ner. Repl ace the
bushi ng i f worn or scored.
Exami ne the seal i ng surfaces of both case hal ves
and retai ners. Smal l burrs, or scratches on these sur-
faces can be reduced wi th crocus cl oth or a fi ne tooth
fi l e.
Exami ne condi ti on of the shi ft rai l bushi ng i n the
front case. I f the bushi ng i s worn or damaged, i t can
be removed wi th a bl i nd hol e type pul l er. A repl ace-
ment bushi ng can be i nstal l ed wi th a sui tabl e si ze
dri ver. Recess the bushi ng sl i ghtl y bel ow the edge of
the bore but do not seat i t al l the i nto the case.
GEARTRAIN
I nspect the mai nshaft spl i nes, gear teeth and bear-
i ng surfaces careful l y for evi dence of wear, or dam-
age. Repl ace the shaft i f necessary. do not attempt to
sal vage i t i f damaged.
The shi ft rai l and range fork are an assembl y.
Repl ace both parts i f ei ther i s damaged. However, the
nyl on pads i n the fork can be repl aced i f worn, or
cracked.
I nspect the transfer case snap ri ngs cl osel y. Do not
attempt to sal vage a di storted snap ri ng by strai ght-
eni ng or reshapi ng i t. Repl ace any snap ri ng that i s
di storted, or worn.
I nspect the l ow range gear, i nput gear and the gear
thrust washers retai ner, and snap ri ng. The l ow
range gear i s servi ced as an assembl y onl y. Repl ace
the gear i f the case or pi ni ons are damaged.
Duri ng i nspecti on, al so make sure the seal surface
of the i nput gear i s i n good condi ti on. Mi nor ni cks on
thi s surface can be reduced wi th crocus cl oth. How-
ever, repl ace the gear i f the seal surface i s severel y
scored or worn.
The speedometer gear shoul d be repl aced i f worn,
cracked, or i f the smal l spl i ne teeth are worn.
OIL PUMP AND VISCOUS COUPLING
The oi l pump and vi scous coupl i ng are not servi ce-
abl e components. Repl ace the coupl i ng as an assem-
bl y i f i t i s l eaki ng or damaged. Repl ace the oi l pump
as an assembl y i f the gear teeth are worn, or i f the
pump has become damaged.
BEARINGS AND SEALS
The transfer case seal s shoul d be repl aced duri ng
overhaul . Use new seal s i n the i nput gear beari ng
retai ner, front case and rear retai ner. Al so repl ace
the yoke seal washer and the detent pl ug O-ri ng.
Check condi ti on of each transfer case beari ng.
Repl ace any beari ng exhi bi ti ng si gns of roughness,
wear, or damage.
ADJ USTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shi ft transfer case i nto Neutral posi ti on.
Fig. 83 Low Range Annulus Gear Location
LOW RANGE ANNULUS GEAR SHIFT RAIL BUSHING
21 - 176 TRANSMISSION AND TRANSFER CASE ZG
CLEANING AND INSPECTION (Continued)
(2) Rai se vehi cl e on hoi st that wi l l al l ow al l four
wheel s to rotate freel y.
(3) Loosen trunni on l ock bol t (Fi g. 84). Loosen bol t
enough so sel ector rod sl i des freel y i n trunni on.
(4) Veri fy that shi ft l ever on transfer case i s i n
Neutral posi ti on.
(5) Ti ghten trunni on l ock bol t to 11-20 Nm
(96-180 i n. l bs.) torque.
(6) Lower vehi cl e enough for entry i nto dri ver seat
but keep al l wheel s off shop fl oor.
(7) Veri fy correct l i nkage adjustment. Start engi ne,
shi ft transmi ssi on i nto gear and shi ft transfer case
i nto al l ranges. Be sure transfer case i s ful l y engaged
i n hi gh and l ow range. Readjust l i nkage i f necessary.
(8) Shut engi ne off and l ower vehi cl e compl etel y.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Bolt, crossmember . . . . . 41-47 Nm (30-35 ft. l bs.)
Plug, Detent . . . . . . . . . . 16-24 Nm (12-18 ft. l bs.)
Plugs, drain/fill . . . . . . . 41-54 Nm (30-40 ft. l bs.)
Switch, Electric . . . . . . . 20-34 Nm (15-25 ft. l bs.)
Bolts, front brg.
retainer . . . . . . . . . . . . 16-24 Nm (12-18 ft. l bs.)
Bolts, case half . . . . . . . . 27-34 Nm (20-25 ft. l bs.)
Nut, output yoke . . . 122176 Nm (90-130 ft. l bs.)
Bolts, rear extension . . . 27-34 Nm (20-25 ft. l bs.)
Lock-nut, shift . . . . . . . . 27-34 Nm (20-25 ft. l bs.)
Bolt, shift rod . . . . . . . . 11-20 Nm (96-180 i n. l bs.)
Nuts, T-case mount
stud . . . . . . . . . . . . . . . 33-41 Nm (24-30 ft. l bs.)
Bolt, U-joint clamp . . . . 16-22 Nm (12-16 ft. l bs.)
Fig. 84 Transfer Case Shift Linkage
TORQUE
(2735 in. lbs.)
(97123 in. lbs.)
(72120 in. lbs.)
RIVNUT (4) SHIFT LEVER ASSEMBLY FLOORPAN TRUNNION LOCK BOLT SELECTOR ROD AND TRUN- NION SHIFT LEVER ROD TORQUE SHAFT FRAME BRACKET TORQUE SHAFT TRANSFER CASE SHIFT LEVER TORQUE SHAFT TRANSFER CASE BRACKET
ZG TRANSMISSION AND TRANSFER CASE 21 - 177
ADJ USTMENTS (Continued)
SPECIAL TOOLS
NV249 TRANSFER CASE
Installer5066
Installer6952-A
Installer6953
Remover6957
InstallerC-3995-A
HandleC-4171
Installer8145
RemoverC-4210
21 - 178 TRANSMISSION AND TRANSFER CASE ZG
RemoverL-4454
Cup8148
Installer8128
Installer7884
ZG TRANSMISSION AND TRANSFER CASE 21 - 179
SPECIAL TOOLS (Continued)
TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
AX15 MANUAL TRANSMISSION . . . . . . . . . . . . 1 NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . 7
AX15 MANUAL TRANSMISSION
GENERAL INFORMATION
AX 15 MANUAL TRANSMISSION
The AX 15 i s a 5speed, synchromesh, manual
transmi ssi on. Fi fth gear i s an overdri ve range wi th a
rati o of 0.79:1. The shi ft mechani sm i s i ntegral and
mounted i n the shi ft tower porti on of the adapter
housi ng (Fi g. 1).
TRANSMISSION IDENTIFICATION
The AX 15 i denti fi cati on code numbers are on the
bottom surface of the transmi ssi on gear case (Fi g. 2).
The fi rst number i s year of manufacture. The sec-
ond and thi rd numbers i ndi cate month of manufac-
ture. The next seri es of numbers i s the transmi ssi on
seri al number.
Fig. 1 AX 15 Manual Transmission
Fig. 2 Identification Code Number Location
ZG TRANSMISSION AND TRANSFER CASE 21 - 1
TRANSMISSION SHIFT PATTERN
The AX 15 shi ft pattern i s shown i n (Fi g. 3). Fi rst
and second and thi rd and fourth gear ranges are i n
l i ne for i mproved shi fti ng. Fi fth and reverse gear
ranges are al so i n l i ne at the extreme ri ght of the
pattern (Fi g. 3).
The AX 15 i s equi pped wi th a reverse l ockout
mechani sm. The shi ft l ever must be moved through
the Neutral detent before maki ng a shi ft to reverse.
TRANSMISSION LUBRICANT
Recommended l ubri cant for AX 15 transmi ssi ons i s
Mopar 75W90, API Grade GL5 gear l ubri cant, or
equi val ent.
Correct l ubri cant l evel i s from the bottom edge, to
no more than 6 mm (1/4 i n.) bel ow the bottom edge of
the fi l l pl ug hol e.
Approxi mate dry fi l l l ubri cant capaci ty i s:
3.10 l i ters (3.27 qts.) i n 4wheel dri ve model s
TRANSMISSION SWITCH AND PLUG LOCATIONS
The fi l l pl ug i s at the dri ver si de of the gear case
(Fi g. 4).
The drai n pl ug and backup l i ght swi tch are on the
passenger si de of the gear case (Fi g. 5).
TRANSMISSION GEAR RATIOS
AX 15 gear rati os are:
Fi rst gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83:1
Second gear . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33:1
Thi rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44:1
Fourth gear . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
Fi fth gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.79:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22:1
TRANSMISSION ASSEMBLY INFORMATION
Lubri cate the transmi ssi on components wi th gear
l ubri cant duri ng assembl y. Use petrol eum jel l y to
l ubri cate seal l i ps and/or hol d parts i n pl ace duri ng
i nstal l ati on.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the gear
case, i ntermedi ate pl ate and adapter or extensi on
housi ng, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l usual l y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a nonrecommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
Fig. 3 AX 15 Shift Pattern
Fig. 4 Fill Plug Location
Fig. 5 Drain Plug/Backup Light Switch Location
21 - 2 TRANSMISSION AND TRANSFER CASE ZG
GENERAL INFORMATION (Continued)
severe, i t may al so contami nate the cl utch di sc caus-
i ng sl i p, grab and chatter.
Transmi ssi ons fi l l ed from ai r or el ectri cal l y pow-
ered l ubri cant contai ners can be under fi l l ed. Thi s
general l y happens when the contai ner del i very mech-
ani sm i s i mproperl y cal i brated. Al ways check the
l ubri cant l evel after fi l l i ng to avoi d an under fi l l con-
di ti on.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel ; use a dri veon hoi st to
ensure thi s. Al so al l ow the l ubri cant to settl e for a
mi nute or so before checki ng. These recommenda-
ti ons wi l l ensure an accurate check and avoi d an
underorover fi l l condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper or contami nated l ubri cants, compo-
nent damage, i ncorrect cl utch adjustment, or by a
damaged cl utch pressure pl ate or di sc.
Substanti al l ubri cant l eaks can resul t i n gear, shi ft
rai l , synchro and beari ng damage. I f a l eak goes
undetected for an extended peri od, the fi rst i ndi ca-
ti ons of a probl em are usual l y hard shi fti ng and
noi se.
I ncorrect or contami nated l ubri cants can al so con-
tri bute to hard shi fti ng. The consequence of usi ng
nonrecommended l ubri cants i s noi se, excessi ve
wear, i nternal bi nd and hard shi fti ng.
I mproper cl utch rel ease i s a frequent cause of hard
shi fti ng. I ncorrect adjustment or a worn, damaged
pressure pl ate or di sc can cause i ncorrect rel ease. I f
the cl utch probl em i s advanced, gear cl ash duri ng
shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear
cl ash when shi fti ng i nto any forward gear. I n some
new or rebui l t transmi ssi ons, new synchro ri ngs may
tend to sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n
most cases, thi s condi ti on wi l l decl i ne as the ri ngs
weari n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears can generate a
mi l d whi ne that may onl y be audi bl e at extreme
speeds.
Severe, obvi ousl y audi bl e transmi ssi on noi se i s
general l y the resul t of a l ubri cant probl em. I nsuffi -
ci ent, i mproper, or contami nated l ubri cant can pro-
mote rapi d wear of gears, synchros, shi ft rai l s, forks
and beari ngs. The overheati ng caused by a l ubri cant
probl em, can al so l ead to gear breakage.
REMOVAL AND INSTALLATION
TRANSMISSION
REMOVAL
1. Di sconnect the battery negati ve cabl e.
2. Remove the shi fter boot and shi fter.
3. Rai se the vehi cl e on a hoi st.
4. Drai n the transmi ssi on fl ui d (Fi g. 6).
5. Support the engi ne and transmi ssi on wi th an
adjustabl e jack stand.
6. Remove exhaust pi pe and heat shi el d.
7. Mark the front and rear propel l er shafts for
i nstal l ati on al i gnment (Fi g. 7).
8. Remove the front propel l er shaft.
9. Remove the rear propel l er shaft.
10. Remove the transmi ssi on ski d pl ate.
Fig. 6 Drain Plug and Backup Light Switch Location
Fig. 7 Marking Propeller Shaft and Axle Yoke
ZG TRANSMISSION AND TRANSFER CASE 21 - 3
DIAGNOSIS AND TESTING (Continued)
11. Di sconnect the transfer case l i nkage and vehi -
cl e speed sensor el ectri cal connector and vent tube
hose (Fi g. 8).
12. Reposi ti on the adjustabl e jackstand under the
engi ne.
13. Pl ace a transmi ssi on jack under the transmi s-
si on and secure the transmi ssi on wi th safety chai ns.
14. Remove the rear transmi ssi on mount.
15. Remove the rear crossmember.
16. Remove the transfer case assembl y. Refer to
Transfer Case removal l ater i n thi s Group.
17. Lower the engi ne and transmi ssi on no more
than 7.6 cm.
18. Remove the two (2) upper and two (2) mi d
cl utch housi ng to engi ne bol ts.
19. Remove the engi ne speed sensor (crankshaft
posi ti on sensor) (Fi g. 9).
20. Remove the cl utch sl ave cyl i nder from the
cl utch housi ng.
21. Remove the l ower transmi ssi on bol ts.
22. Remove the transmi ssi on assembl y from the
vehi cl e.
INSTALLATION
1. Mount the transmi ssi on on a transmi ssi on jack
and secure the transmi ssi on wi th safety chai ns.
2. I nstal l the transmi ssi on to the vehi cl e (Fi g. 10).
3. I nstal l the two (2) l ower transmi ssi on bol ts.
Ti ghten the bol ts to 74.6 Nm.
4. I nstal l the cl utch sl ave cyl i nder to the cl utch
housi ng.
5. I nstal l the engi ne speed sensor (crankshaft posi -
ti on sensor) to the vehi cl e (Fi g. 9).
6. I nstal l the two (2) upper cl utch housi ng to
engi ne bol ts. Ti ghten the bol ts to 36.6 Nm.
7. I nstal l the two (2) mi d cl utch housi ng to engi ne
bol ts. Ti ghten the bol ts to 58.3 Nm.
8. Rai se the engi ne and transmi ssi on wi th the
adjustabl e jackstand.
9. I nstal l the transfer case assembl y. Refer to
Transfer Case i nstal l ati on l ater i n thi s Group.
10. I nstal l the rear crossmember.
11. I nstal l the rear transmi ssi on mount.
12. Connect the transfer case l i nkage and vehi cl e
speed sensor el ectri cal connector and vent tube (Fi g.
8).
13. I nstal l the transmi ssi on ski d pl ate.
14. Al i gn and i nstal l the front and rear propel l er
shafts.
15. I nstal l the exhaust pi pe and heat shi el d.
16. Remove the transmi ssi on jack.
17. Fi l l the transmi ssi on wi th the proper fl ui d
(Fi g. 12).
18. Remove the adjustabl e jackstand from under
the engi ne.
19. Lower the vehi cl e from the hoi st.
20. I nstal l the shi fter boot and shi fter.
21. Reconnect the battery negati ve cabl e.
Fig. 8 Vehicle Speed Sensor
Fig. 9 Engine Speed Sensor
21 - 4 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
Fig. 10 Transmission to Engine Mounting
Fig. 11 Clutch Housing to Transmission
Fig. 12 Fill Plug Location
ZG TRANSMISSION AND TRANSFER CASE 21 - 5
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Cl utch Housi ng to Engi ne
Top (2) Bol ts . . . . . . . . . . . . 36.6 Nm (27 ft. l bs.)
Cl utch Housi ng to Engi ne
Mi d-Poi nt (2) Bol ts . . . . . . . 58.3 Nm (43 ft. l bs.)
Cl utch Housi ng to Engi ne
Bottom (2) Bol ts . . . . . . . . . . 74.6 Nm (55 ft. l bs.)
Cl utch Housi ng to Transmi ssi on
bol ts . . . . . . . . . . . . . . . . . . . 38.0 Nm (28 ft. l bs.)
Transfer Case to Transmi ssi on
Attachi ng Nuts . . . . . . . . . . . . 35 Nm (26 ft. l bs.)
Propel l er Shaft Bol ts . . . . . . . 26.5 Nm (19.5 ft. l bs.)
21 - 6 TRANSMISSION AND TRANSFER CASE ZG
NV231 TRANSFER CASE
GENERAL INFORMATION
NV231 TRANSFER CASE
The NV231 i s a part-ti me transfer case wi th a l ow
range reducti on gear system. The NV231 has three
operati ng ranges pl us a Neutral posi ti on. A l ow range
system provi des a reducti on rati o for i ncreased l ow
speed torque capabi l i ty.
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range hub. The
front output shaft i s operated by a dri ve chai n that
connects the shaft to a dri ve sprocket on the mai n-
shaft. The dri ve sprocket i s engaged/di sengaged by
the mode fork, whi ch operates the mode sl eeve and
hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
Transfer case operati ng ranges are:
2WD (2-wheel dri ve)
4x4 (4-wheel dri ve)
4 Lo (4-wheel dri ve l ow range
The 2WD range i s for use on any road surface at
any ti me.
The 4x4 and 4 Lo ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s covered by
i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4 Lo range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a fl oor mounted
shi ft l ever. The shi ft l ever i s connected to the trans-
fer case range l ever by an adjustabl e l i nkage rod. A
strai ght l i ne shi ft pattern i s used. Range posi ti ons
are marked on the shi fter bezel cover pl ate.
TRANSFER CASE IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
RECOMMENDED LUBRICANT AND FILL LEVEL
Recommended l ubri cant for the NV231 transfer
case i s Mopar Dexron I I , or ATF Pl us. Approxi mate
l ubri cant fi l l capaci ty i s 1.2 l i ters (2.5 pi nts).
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 1). Correct fi l l l evel i s to the bottom edge of the
fi l l pl ug hol e. Be sure the vehi cl e i s l evel to ensure
an accurate fl ui d l evel check.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations
ZG TRANSMISSION AND TRANSFER CASE 21 - 7
DIAGNOSIS AND TESTING
NV231 DIAGNOSIS
21 - 8 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(2) Rai se vehi cl e.
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
al i gnment reference.
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember and ski d pl ate, i f
equi pped.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 2)
and i ndi cator swi tch harness, i f necessary.
(11) Support transfer case wi th transmi ssi on jack.
(12) Secure transfer case to jack wi th chai ns.
(13) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(2) Secure transfer case to jack wi th chai ns.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (Fi g. 2).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch, i f necessary. Secure wi re harness to cl i ps
on transfer case.
(8) Al i gn and connect propel l er shafts. Ti ghten
shaft attachi ng bol ts to 26.5 Nm torque.
(9) Fi l l transfer case wi th correct fl ui d. Refer to
Recommended Lubri cant And Fi l l Level secti on for
proper fl ui d and capaci ty.
(10) I nstal l rear crossmember and ski d pl ate, i f
equi pped. Ti ghten crossmember bol ts.
(11) Remove transmi ssi on jack and support stand.
(12) Connect shi ft rod to transfer case range l ever.
(13) Adjust transfer case shi ft l i nkage.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(2) Remove transfer case shi fter knob cap.
(3) Remove nut hol di ng shi fter knob to shi ft l ever.
(4) Remove shi fter knob.
(5) Rai se and support vehi cl e.
(6) Loosen adjusti ng trunni on l ock bol t and sl i de
shi ft rod out of trunni on (Fi g. 3). I f rod l acks enough
travel to come out of trunni on, push trunni on out of
shi ft l ever.
(7) Remove bol ts hol di ng shi ft l ever to transmi s-
si on.
(8) Separate shi ft l ever from vehi cl e.
Fig. 2 Transfer Case Mounting
Fig. 3 Shift Lever
ZG TRANSMISSION AND TRANSFER CASE 21 - 9
INSTALLATION
(1) Posi ti on shi ft l ever on transmi ssi on. Use care
when passi ng the shi ft l ever through the shi fter boot
to prevent damage to the shi fter boot.
(2) I nstal l bol ts to hol d shi ft l ever to transmi ssi on.
(3) I nstal l trunni on to shi ft l ever, i f necessary.
(4) I nstal l shi ft rod to trunni on, i f necessary.
(5) Move shi ft l ever and transfer case to 4L posi -
ti on.
(6) Ti ghten trunni on l ock bol t.
(7) Lower vehi cl e.
(8) I nstal l shi ft knob on shi ft l ever.
(9) I nstal l nut to hol d shi fter knob to shi ft l ever.
(10) I nstal l shi fter knob cap.
(11) Veri fy transfer case operati on.
SPEEDOMETER
REMOVAL
(1) Rai se vehi cl e.
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 4).
(4) Remove speed sensor and speedometer adapter
as an assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
Repl ace pi ni on i f chi pped, cracked, or worn.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 4).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar el ectri cal spray cl eaner i f di rty
oroxi di zed. Repl ace sensor i f faul ty, or i f pi ns are
l oose, severel y corroded, or damaged.
INSTALLATION AND INDEXING
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter (Fi g. 4), i f necessary.
(3) Lubri cate sensor and adapter O-ri ngs wi th
transmi ssi on fl ui d.
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 Nm
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 5).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 Nm (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel i f necessary.
Fig. 4 Speedometer Components
21 - 10 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove front propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
6).
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143 as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 7). Once seal i s started, conti nue tappi ng
seal i nto bore unti l i nstal l er tool seats agai nst case.
REAR RETAINER BUSHING AND SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove rear propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear retai ner seal .
(4) Usi ng Remover 6957, remove bushi ng from
rear retai ner (Fi g. 8).
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Posi ti on repl acement bushi ng i n rear retai ner
wi th fl ui d port i n bushi ng al i gned wi th sl ot i n
retai ner.
Fig. 5 Location Of Index Numbers On Speedometer
Adapter
Fig. 6 Remove Front Output Shaft Seal
Fig. 7 Front Output Seal Installation
Fig. 8 Rear Retainer Bushing Removal
ZG TRANSMISSION AND TRANSFER CASE 21 - 11
REMOVAL AND INSTALLATION (Continued)
(3) Usi ng I nstal l er 8160, dri ve bushi ng i nto
retai ner unti l i nstal l er seats agai nst case (Fi g. 9).
(4) Usi ng I nstal l er C-3995-A, i nstal l seal i n rear
retai ner (Fi g. 10).
(5) I nstal l propel l er shaft.
(6) Veri fy proper fl ui d l evel .
(7) Lower vehi cl e.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Drai n/Fi l l . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Nuts, Mounti ng . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Swi tch, I ndi cator . . . . . . . . . . . . . . . . . . . . . 26 Nm
SPECIAL TOOLS
SPECIAL TOOLS NV231
Fig. 9 Rear Retainer Bushing Install
Fig. 10 Install Rear Retainer Seal
Installer, Seal8143
Remover, Bushing6957
Installer, Bushing8160
Installer, SealC-3995-A
21 - 12 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
TIRES AND WHEELS
CONTENTS
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRES
INDEX
page page
DESCRIPTION AND OPERATION
RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . . . 2
REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . 3
SPARE TIRE (TEMPORARY) . . . . . . . . . . . . . . . 2
TIRE INFLATION PRESSURES . . . . . . . . . . . . . 2
TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . 1
TIRE PRESSURE FOR HIGHSPEED
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . . 3
TIRE NOISE OR VIBRATION . . . . . . . . . . . . . . . 4
TIRE WEAR PATTERNS . . . . . . . . . . . . . . . . . . . 3
TREAD WEAR INDICATORS . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
MATCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . 4
REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . . . 5
ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING AND INSPECTION
CLEANING OF TIRES . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION
TIRE INFORMATION
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl es requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n, i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
Rapi d accel erati on
Severe appl i cati on of brakes
Hi gh-speed dri vi ng
Taki ng turns at excessi ve speeds
Stri ki ng curbs and other obstacl es
Radi al pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val shown i n the secti on on Ti re Rotati on. Thi s wi l l
hel p to achi eve a greater tread-l i fe potenti al .
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 1).
Performance ti res wi l l have a speed rati ng l etter
after the aspect rati o number. The speed rati ng i s not
al ways pri nted on the ti re si dewal l . The l etter S i ndi -
cates that the ti re i s speed rated up to 112 mph.
Q up to 100 mph
T up to 118 mph
U up to 124 mph
H up to 130 mph
V up to 149 mph
Z more than 149 mph (consul t the ti re manu-
facturer for the speci fi c speed rati ng)
An Al l Season type ti re wi l l have ei ther M +S, M
& S or MS (i ndi cati ng mud and snow tracti on)
i mpri nted on the si de wal l .
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to Owners Manual for more i nformati on.
ZG TIRES AND WHEELS 22 - 1
RADIAL-PLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe, ri de
qual i ty and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of four
and under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
I t i s recommended that ti res from di fferent manu-
factures NOT be mi xed. The proper ti re pressure
shoul d be mai ntai ned on al l four ti res. For proper
ti re pressure refer to the Ti re I nfl ati on Pressure
Chart provi ded wi th the vehi cl e.
SPARE TIRE (TEMPORARY)
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
and rei nstal l ed at the fi rst opportuni ty, or a new ti re
purchased. Do not exceed speeds of 50 MPH. Refer to
Owners Manual for compl ete detai l s.
TIRE INFLATION PRESSURES
Under i nfl ati on causes rapi d shoul der wear, ti re
fl exi ng, and can resul t i n ti re fai l ure (Fi g. 2).
Over i nfl ati on causes rapi d center wear and l oss of
the ti res abi l i ty to cushi on shocks (Fi g. 3).
I mproper i nfl ati on can cause:
Uneven wear patterns
Reduced tread l i fe
Reduced fuel economy
Unsati sfactory ri de
The vehi cl e to dri ft.
For proper ti re pressure speci fi cati on refer to the
Ti re I nfl ati on Pressure Chart provi ded wi th the vehi -
cl e.
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once per month.
Check ti re pressure more frequentl y when the
Fig. 1 Tire Identification
METRIC TIRE SIZES P 205 / 75 R 15 TIRE TYPE P - PASSENGER T - TEMPORARY C - COMMERCIAL LT - LIGHT TRUCK SECTION WIDTH (MILLIMETERS) 185 195 205 ETC. ASPECT RATIO (SECTION HEIGHT) (SECTION WIDTH) 70 75 80 CONSTRUCTION TYPE R - RADIAL B - BIAS BELTED D - DIAGONAL (BIAS) RIM DIAMETER (INCHES) 13 14 15 16 SECTION WIDTH SECTIONHEIGHT
Fig. 2 Under Inflation Wear
THIN TIRE THREAD AREAS
Fig. 3 Over Inflation Wear
THIN TIRE THREAD AREA
22 - 2 TIRES AND WHEELS ZG
DESCRIPTION AND OPERATION (Continued)
weather temperature vari es wi del y. Ti re pressure wi l l
decreases when the outdoor temperature drops.
I nfl ati on pressures speci fi ed on the pl acards are
al ways col d i nfl ati on pressure. Col d i nfl ati on pres-
sure i s obtai ned after the vehi cl e has not been oper-
ated for at l east 3 hours. Or the vehi cl e i s dri ven l ess
than one mi l e after bei ng i noperati ve for 3 hours.
Ti re i nfl ati on pressures may i ncrease from 2 to 6
pounds per square i nch (psi ) duri ng operati on. Do not
reduce thi s normal pressure bui l d-up.
WARNING: OVER OR UNDER INFLATED TIRES
CAN AFFECT VEHICLE HANDLING. THE TIRE CAN
FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL.
TIRE PRESSURE FOR HIGHSPEED OPERATION
Chrysl er Corporati on advocates dri vi ng at safe
speeds wi thi n posted speed l i mi ts. Where speed l i m-
i ts al l ow the vehi cl e to be dri ven at hi gh speeds, cor-
rect ti re i nfl ati on pressure i s very i mportant. For
speeds up to and i ncl udi ng 75 mph (120 km/h), ti res
must be i nfl ated to the pressures shown on the ti re
pl acard. For conti nuous speeds i n excess of 75 mph
(120 km/h), ti res must be i nfl ated to the maxi mum
pressure speci fi ed on the ti re si dewal l .
Vehi cl es l oaded to the maxi mum capaci ty shoul d
not be dri ven at conti nuous speeds above 75 mph
(120 km/h).
For emergency vehi cl es that are dri ven at speeds
over 90 mph (144 km/h), speci al hi gh-speed ti res
must be used. Consul t ti re manufacturer for correct
i nfl ati on pressure recommendati ons.
REPLACEMENT TIRES
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
Ri de
Noi se
Handl i ng
Durabi l i ty
Tread l i fe
Tracti on
Rol l i ng resi stance
Speed capabi l i ty
I t i s recommend that ti res equi val ent to the ori gi -
nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res not l i sted i n the speci fi ca-
ti on charts may cause i nterference wi th vehi cl e com-
ponents. Under extremes of suspensi on and steeri ng
travel , i nterference wi th vehi cl e components may
cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DIAGNOSIS AND TESTING
PRESSURE GAUGES
A hi gh-qual i ty ai r-pressure gauge i s recommended
to check ti re pressure. After checki ng wi th the gauge,
repl ace val ve caps and fi nger ti ghten.
TREAD WEAR INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band.
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs (Fi g. 4).
TIRE WEAR PATTERNS
Under i nfl ati on resul ts i n faster wear on shoul ders
of ti re. Over i nfl ati on causes faster wear at center of
tread.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s worn more
than the other.
Excessi ve toe-i n or toe-out causes wear on the
tread edges of the ti re, from draggi ng of ti re. There i s
a feathered effect across the tread (Fi g. 5).
Fig. 4 Tread WearIndicators
THREAD ACCEPTABLE THREAD UNACCEPTABLE WEAR INDICATOR
ZG TIRES AND WHEELS 22 - 3
DESCRIPTION AND OPERATION (Continued)
TIRE NOISE OR VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the effect of accel erati on and decel era-
ti on on noi se l evel . Di fferenti al and exhaust noi ses
wi l l change i n i ntensi ty as speed vari es, whi l e ti re
noi se wi l l usual l y remai n constant.
SERVICE PROCEDURES
ROTATION
Ti res on the front and rear axl es operate at di ffer-
ent l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons;
They wear at unequal rates
Tend to devel op i rregul ar wear patterns
These effects can be reduced by ti mel y rotati on of
ti res. The benefi ts of rotati on are especi al l y worth-
whi l e. Rotati on wi l l :
I ncrease tread l i fe
Hel p to mai ntai n mud, snow, and wet tracti on
l evel s
Contri bute to a smooth, qui et ri de
The suggested method of ti re rotati on i s (Fi g. 6).
Other rotati on methods can be used, but they wi l l
not provi de al l the ti re l ongevi ty benefi ts.
MATCH MOUNTING
NOTE: Tires and wheels are currently match
mounted at the factory.
Match mounti ng i s a techni que used to reduce
runout i n the wheel /ti re assembl y. Thi s means that
the hi gh spot of the ti re i s al i gned wi th the l ow spot
on the wheel ri m. The hi gh spot on the ti re i s
marked wi th a pai nt mark or a bri ght col ored adhe-
si ve l abel on the outboard si dewal l . The l ow spot on
the ri m i s i denti fi ed wi th a l abel on the outsi de of the
ri m and a dot on the i nsi de of the ri m. I f the outsi de
l abel has been removed the ti re wi l l have to be
removed to l ocate the dot on the i nsi de of the ri m.
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
(1) Measure the total i ndi cator runout on the cen-
ter of the ti re tread ri b. Record the i ndi cator readi ng.
Mark the ti re to i ndi cate the hi gh spot. Pl ace a mark
on the ti re at the val ve stem l ocati on (Fi g. 7).
Fig. 5 Tire Wear Patterns
CONDITION RAPID WEAR AT SHOULDERS RAPID WEAR AT CENTER CRACKED TREADS WEAR ON ONE SIDE FEATHERED EDGE BALD SPOTS SCALLOPED WEAR EFFECT CAUSE
UNDER-INFLATION
OR LACK OF ROTA-
TION
OVER-INFLATION
OR LACK OF ROTA-
TION
UNDER-INFLATION OR EXCESSIVE SPEED*
EXCESSIVE CAMBER INCORRECT TOE UNBALANCED WHEEL
OR TIRE DEFECT*
LACK OF ROTATION OF TIRES OR
WORN OR OUT-OF-ALIGNMENT
SUSPENSION.
CORRECTION ADJUST PRES- SURE TO SPEC- IFICATIONS WHEN TIRES ARE COOL ROTATE TIRES ADJUST CAMBER TO SPECIFICATIONS ADJUST TOE-IN TO SPECIFICATIONS DYNAMIC OR STATIC BALANCE WHEELS ROTATE TIRES AND INSPECT SUSPENSION SEE GROUP 2
*HAVE TIRE INSPECTED FOR
FURTHER USE.
Fig. 6 Tire Rotation Pattern
FRONT
22 - 4 TIRES AND WHEELS ZG
DIAGNOSIS AND TESTING (Continued)
(2) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 8).
(3) Measure the total i ndi cator runout agai n. Mark
the ti re to i ndi cate the hi gh spot.
(4) I f runout i s sti l l excessi ve, the fol l owi ng proce-
dures must be done.
I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.) of
the fi rst spot and i s sti l l excessi ve, repl ace the ti re.
I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.) of
the fi rst spot on the wheel , the wheel may be out of
speci fi cati ons. Refer to Wheel and Ti re Runout.
I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 9). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount.
REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 10). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Defl ate ti re compl etel y before di smounti ng ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
torque speci fi cati on.
Fig. 7 First Measurement On Tire
REFER- ENCEMARK 1ST MEASURE- MENT HIGH SPOT MARK TIRE AND RIM WHEEL VALVE STEM
Fig. 8 Remount Tire 180 Degrees
VALVESTEM REFERENCEMARK
Fig. 9 Remount Tire 90 Degrees In Directionof
Arrow
2ND HIGH SPOT ON TIRE 1ST HIGH SPOT ON TIRE
ZG TIRES AND WHEELS 22 - 5
SERVICE PROCEDURES (Continued)
CLEANING AND INSPECTION
CLEANING OF TIRES
Remove protecti ve coati ng on ti res before del i very
of vehi cl e. The coati ng coul d cause deteri orati on of
ti res.
Remove protecti ve coati ng by:
Appl yi ng warm water
Letti ng i t soak one mi nute
Scrubbi ng the coati ng away wi th a soft bri stl e
brush.
Steam cl eani ng may al so be used for cl eani ng.
DO NOT use gasol i ne or wi re brush for cl eani ng.
DO NOT use mi neral oi l or an oi l -based sol vent.
Fig. 10 Tire Repair Area
REPAIR- ABLE AREA
22 - 6 TIRES AND WHEELS ZG
WHEELS
INDEX
page page
DESCRIPTION AND OPERATION
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . 8
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
TIRE AND WHEEL BALANCE . . . . . . . . . . . . . . . 9
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION AND OPERATION
WHEEL
Avai l abl e ri m si zes are on the safety certi fi cati on
l abel l ocated on the dri vers door shut face.
Ri m si ze i s determi ned by the dri vetrai n package.
Ori gi nal equi pment wheel s are desi gned for opera-
ti on up to the speci fi ed maxi mum vehi cl e capaci ty.
Al l model s use steel or cast al umi num wheel s.
Every wheel has rai sed secti ons between the ri m
fl anges and ri m drop wel l cal l ed safety humps (Fi g.
1).
I ni ti al i nfl ati on of the ti re forces the bead over
these rai sed secti ons. I n case of rapi d l oss of ai r pres-
sure, the rai sed secti ons hel p hol d the ti re on the
wheel .
Cast al umi num wheel s requi re coated bal ance
wei ghts and speci al al i gnment equi pment.
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons and must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts wi th an enl arged nose.
Thi s enl arged nose i s necessary to ensure proper
retenti on of the wheel s.
Before i nstal l i ng the wheel , remove any bui l d up of
corrosi on on the wheel mounti ng surfaces.
WARNING: INSTALLING WHEELS WITHOUT GOOD
METAL-TO-METAL CONTACT COULD CAUSE LOOS-
ENING OF WHEEL NUTS. THIS COULD ADVERSELY
AFFECT THE SAFETY AND HANDLING OF YOUR
VEHICLE.
DIAGNOSIS AND TESTING
WHEEL INSPECTION
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY AFFECT
THE SAFETY AND HANDLING OF THE VEHICLE.
WARNING: REPLACEMENT WITH USED WHEELS
IS NOT RECOMMENDED. THE SERVICE HISTORY
OF THE RIM MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
Wheel s must be repl aced i f they:
Have excessi ve run out
Are bent or dented
Leak ai r from any area or surface of the ri m
Have damaged wheel l ug/ nut hol es
Wheel repairs employing hammering, heating,
welding or repairing leaks are not allowed.
Ori gi nal equi pment repl acement wheel s shoul d be
used. When obtai ni ng repl acement wheel s, they
shoul d be equi val ent i n l oad carryi ng capaci ty. The
physi cal di mensi ons (di ameter, wi dth, offset, pi l ot
hol e and bol t ci rcl e) of the wheel shoul d be the same
as the ori gi nal wheel .
Fig. 1 Safety Rim
FLANGE RIDGEWELL
ZG TIRES AND WHEELS 22 - 7
TIRE AND WHEEL RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 2).
Lateral runout i s the wobble of the ti re or wheel .
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of the wheel mounti ng surface;
adjust wheel beari ngs.
Dri ve vehi cl e a short di stance to el i mi nate ti re fl at
spotti ng from a parked posi ti on.
Make sure al l wheel nuts are properl y torqued.
Rel ocate wheel on the mounti ng, two studs over
from the ori gi nal posi ti on.
Re-ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
Check radi al runout. I f sti l l excessi ve, mark ti re
si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotati ng ti re on wheel i s parti cul arl y effecti ve
when there i s runout i n both ti re and wheel .
Remove ti re from wheel and mount wheel on ser-
vi ce dynami c bal ance machi ne.
Check wheel radi al runout (Fi g. 3) and l ateral
runout (Fi g. 4).
STEEL WHEELS: Radi al runout 0.040 i n., Lat-
eral runout 0.045 i n.
ALUMI NUM WHEELS: Radi al runout 0.030 i n.,
Lateral runout 0.035 i n.
I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout, Refer to match mounti ng procedure.
SERVICE PROCEDURES
WHEEL INSTALLATION
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
Fig. 2 Checking Tire/Wheel/Hub Runout
RADIAL RUNOUT LATERAL RUNOUT
Fig. 3 Radial Runout
MOUNTING CONE
SPINDLE SHAFT
WING NUT
Fig. 4 Lateral Runout
MOUNTING CONE
SPINDLE SHAFT
WING NUT
22 - 8 TIRES AND WHEELS ZG
DIAGNOSIS AND TESTING (Continued)
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts. Thi s coul d affect the safety and han-
dl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on (Fi g. 5).
Never use oil or grease on studs or nuts.
WHEEL REPLACEMENT
Wheel s must be repl aced i f they have:
Excessi ve runout
Bent or dented
Leak ai r through wel ds
Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
Load carryi ng capaci ty
Di ameter
Wi dth
Offset
Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
TIRE AND WHEEL BALANCE
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two
plane balancer is not available.
Fig. 5 Lug Nut Tightening Pattern
ZG TIRES AND WHEELS 22 - 9
SERVICE PROCEDURES (Continued)
For stati c i mbal ance, fi nd l ocati on of heavy spot
causi ng i mbal ance. Counter bal ance wheel di rectl y
opposi te the heavy spot. Determi ne wei ght requi red
to counterbal ance the area of i mbal ance. Pl ace hal f of
thi s wei ght on the inner ri m fl ange and the other
hal f on the outer ri m fl ange (Fi g. 6) and (Fi g. 7).
Off-vehi cl e bal anci ng i s necessary.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Lug Nut
1/2 X 20 wi th 60 Cone . . . . . . . . . 109 to 150 Nm
(80 to 110 ft. l bs.)
Fig. 6 Static Unbalance & Balance
HEAVYSPOT OF SPINDLE ADD BALANCE WEIGHTS HERE CORRECTIVE WEIGHT LOCATION TIRE OR WHEEL TRAMP, OR WHEEL HOP
Fig. 7 Dynamic Unbalance & Balance
OF SPINDLE ADD BALANCE WEIGHTS HERE CORRECTIVE WEIGHT LOCATION HEAVY SPOT WHEEL SHIMMY AND VIBRATION
22 - 10 TIRES AND WHEELS ZG
SERVICE PROCEDURES (Continued)
BODY
CONTENTS
page page
BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . 16
GENERAL SERVICE INFORMATION . . . . . . . . . . 1
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER SUNROOF . . . . . . . . . . . . . . . . . . . . . . . 8
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 4
GENERAL SERVICE INFORMATION
INDEX
page
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS . . . . 1
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
Chrysl er Corporati on uses many di fferent types of
push-i n fasteners to secure the i nteri or and exteri or
tri m to the body. Most of these fasteners can be
reused to assembl e the tri m duri ng vari ous repai r
procedures. At ti mes, a push-i n fastener cannot be
removed wi thout damagi ng the fastener or the com-
ponent i t i s hol di ng. I f i t i s not possi bl e to remove a
fastener wi thout damagi ng a component or body, cut
or break the fastener and use a new one when
i nstal l i ng the component. Never pry or pound on a
pl asti c or pressed-board tri m component. Usi ng a
sui tabl e fork-type pryi ng devi ce, pry the fastener
from the retai ni ng hol e behi nd the component bei ng
removed. When i nstal l i ng, veri fy fastener al i gnment
wi th the retai ni ng hol e by hand. Push di rectl y on or
over the fastener unti l i t seats. Appl y a l ow-force pul l
to the panel to veri fy that i t i s secure.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges hol di ng the component i n
pl ace.
ZG BODY 23 - 1
PAINT
INDEX
page page
GENERAL INFORMATION
BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . 2
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PAINTED SURFACE TOUCHUP . . . . . . . . . . . . . 2
WET SANDING, BUFFING, AND POLISHING . . . 2
SPECIFICATIONS
AFTER MARKET PAINT REPAIR PRODUCTS . . 3
GENERAL INFORMATION
PAINT CODE
Exteri or vehi cl e body col ors are i denti fi ed on the
Body Code pl ate. The pl ate i s l ocated on the top,
ri ght si de of the dash panel bel ow the cowl gri l l e i n
the engi ne compartment. Refer to the I ntroducti on
secti on at the front of thi s manual for body code
pl ate descri pti on. The pai nt code i s al so i denti fi ed on
the Vehi cl e Safety Certi fi cati on Label whi ch i s
l ocated on the dri vers door shut face. The col or
names provi ded i n the Pai nt and Tri m Code Descri p-
ti on chart are the col or names used on most repai r
product contai ners.
BASE COAT/CLEAR COAT FINISH
On most vehi cl es a two-part pai nt appl i cati on (base
coat/cl ear coat) i s used. Col or pai nt that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
WET SANDING, BUFFING, AND POLISHING
Mi nor aci d etchi ng, orange peel , or smudgi ng i n
cl ear coat or si ngl e-stage fi ni shes can be reduced
wi th l i ght wet sandi ng, hand buffi ng, and pol i shi ng.
If the finish has been wet sanded in the past, it
cannot be repeated. Wet sanding operation
should be performed by a trained automotive
paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
PAINTED SURFACE TOUCHUP
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. Refer to I ntroducti on group of thi s manual for
Body Code Pl ate i nformati on.
TOUCHUP PROCEDURE
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the defect wi thout runni ng. Do
not stroke brush appl i cator on body surface. Al l ow
the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touchup col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touchup
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touchup
col or can be l i ghtl y wet sanded (1500 gri t) and pol -
i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, appl y cl ear top coat
to touchup pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
23 - 2 BODY ZG
SPECIFICATIONS
AFTER MARKET PAINT REPAIR PRODUCTS
EXTERIOR COLOR
CLADDING COLOR
INTERIOR COLOR
EXTERIOR COLOR
CHRY
CODE
*
PPG BASF DuPONT
S-W ACME
M-S
AKZO/NOBEL
SIKKENS
Dark Rosewood Pearl Coat REG 27558 25041 B9519 50266 CHA95:REG
Flame Red Clear Coat PR4 4679 23043 B9326 46916 CHA93:PR4
Char Gold II Satin Glow RJ7 35748 25037 B9532 50278 CHA95:RJ7
Moss Green Pearl Coat RJN 47383 25036 B9533 50277 CHA95:RJN
Forest Green Pearl Coat SG8 47439 26078 B9609 51062 CHA95:SG8
Deep Amethyst Pearl Coat TCN 5246 27038 B9736 52026 CHA97:TCN
Bright Metallic Clear Coat MS4 4820 24082 B9642 48823 CHA94:MS4
Black Clear Coat DX8 9700 15214 99 34858 90-5950 CHA85:DX8
Opal Satin Glow SW4 93541 26090 B9621 51538 CHA96:SW4
Stone White Clear Coat SW1 83542 26089 B9622 51540 CHA96:SW1
CLADDING
COLOR
CHRY
CODE
*
PPG BASF DuPONT
S-W
ACME
M-S
AKZO/NOBEL
SIKKENS
Flame Red PR4 4679 23043 B9326 46916 CHAPR4M
Medium Driftwood MFD 27360 23054 C9321 48024 CHA93:MFD
Dark Rosewood REG 4966 25041 B9519 50266 CHAREGM
Deep Hunter Green SG8 47439 26078 B9609 51062 CHASG8M
Moss Green RJN 47383 25036 B9533 50277 CHARJNM
Black DX8 9700 15214 F0204 34858
90-5950
CHADX8M
Dark Neutral Gray HS5 34349 20215 C8923 40392 CHA90:HS5
Radiant Silver CA1 34852 14220 C8312 33432 CHACA1M
Bright Platinum MS4 4820 24082 B9462 48823 CHAMS4M
Stone White SW1 83542 26089 B9622 51539 CHASW1M
*Herberts Standox and Spi es Hecker use the Chrysl er pai nt code as l i sted on the Body Code Pl ate and the
Vehi cl e Safety Certi fi cati on l abel .
INTERIOR
COLOR
CHRY CODE PPG BASF DuPONT S-W ACME M-S
Agate AZ 9856/2-1461 22135 C9208 45994
Mist Gray C3 35799/2-1576 25065 C9507 50508
Saddle T6 27917/2-1594 26121 C9603 51541
Saddle/ Moss
Green (RT6/RJ4)
TJ N/A 26121 25069 C9604 C9513 51542 50512
ZG BODY 23 - 3
STATIONARY GLASS
INDEX
page page
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . 7
QUARTER WINDOW GLASS . . . . . . . . . . . . . . . 5
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCHWELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURERS DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
I t i s di ffi cul t to sal vage a wi ndshi el d duri ng the
removal operati on. The wi ndshi el d i s part of the
structural support for the roof. The urethane bondi ng
used to secure the wi ndshi el d to the fence i s di ffi cul t
to cut or cl ean from any surface. I f the mol di ngs are
set i n urethane, i t woul d al so be unl i kel y they coul d
be sal vaged. Before removi ng the wi ndshi el d, check
the avai l abi l i ty of the wi ndshi el d and mol di ngs from
the parts suppl i er.
REMOVAL AND INSTALLATION
WINDSHIELD
REMOVAL
(1) Remove i nsi de rear vi ew mi rror.
(2) Remove cowl cover.
(3) Remove screws attachi ng wi ndshi el d si de mol d-
i ng to A-pi l l ar (Fi g. 1).
(4) Remove upper wi ndshi el d mol di ng.
(5) Cut urethane bondi ng from around wi ndshi el d
usi ng a sui tabl e sharp col d kni fe. A pneumati c cut-
ti ng devi ce can be used i f avai l abl e (Fi g. 2).
(6) Separate wi ndshi el d from vehi cl e.
INSTALLATION
WARNING: Allow the urethane at least 4 hours to
cure before returning the vehicle to use.
CAUTION: Open a window before installing wind-
shield. This will avoid pressurizing the passenger
compartment. If a door or liftgate is slammed before
urethane is cured, water leaks can result.
The wi ndshi el d fence shoul d be cl eaned of ol d ure-
thane bondi ng materi al . Support spacers shoul d be
cl eaned and properl y i nstal l ed on wel d studs or
repai r screws at bottom of wi ndshi el d openi ng.
(1) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng. Posi ti on gl ass i n the center of the openi ng
agai nst the support spacers. Mark the gl ass at the
support spacers wi th a grease penci l or maski ng tape
and i nk pen to use as a reference for i nstal l ati on.
Remove repl acement wi ndshi el d from wi ndshi el d
openi ng (Fi g. 3).
(2) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 4).
23 - 4 BODY ZG
(3) Cl ean i nsi de of wi ndshi el d wi th Mopar Gl ass
Cl eaner and l i nt-free cl oth.
(4) Appl y cl ear gl ass pri mer 25 mm (1 i n.) wi de
around edge of wi ndshi el d. Wi pe wi th cl ean/dry l i nt-
free cl oth.
(5) Appl y bl ack-out pri mer 15 mm (.75 i n.) wi de on
top and si des of wi ndshi el d and 25 mm (1 i n.) on bot-
tom of wi ndshi el d. Al l ow at l east three mi nutes dry-
i ng ti me.
(6) Posi ti on wi ndshi el d spacers on l ower fence
above support spacers at the edge of the wi ndshi el d
openi ng (Fi g. 1).
(7) Appl y a 10 mm (0.4 i n.) bead of urethane
around peri meter of wi ndshi el d al ong the i nsi de of
the mol di ngs. Appl y two beads al ong the bottom
edge.
(8) I nstal l upper mol di ng onto wi ndshi el d.
(9) Appl y fence pri mer around the peri meter of the
wi ndshi el d openi ng fence. Al l ow at l east 18 mi nutes
dryi ng ti me.
(10) Wi th ai d of a hel per, posi ti on wi ndshi el d over
wi ndshi el d openi ng. Al i gn reference marks at bottom
of wi ndshi el d to support spacers.
(11) Sl owl y l ower wi ndshi el d gl ass to wi ndshi el d
openi ng fence. Gui de top mol di ng i nto proper posi ti on
i f necessary. Push wi ndshi el d i nward to fence spacers
at bottom and unti l top mol di ng i s fl ush to roof l i ne.
(12) Cl ean excess urethane from exteri or wi th
Mopar Super Cl ean or equi val ent.
(13) I nstal l wi ndshi el d si de mol di ngs.
(14) I nstal l cowl cover and wi pers.
(15) I nstal l i nsi de rear vi ew mi rror.
(16) After urethane has cured, water test wi nd-
shi el d to veri fy repai r.
QUARTER WINDOW GLASS
REMOVAL
(1) Cut urethane bondi ng from around quarter
wi ndow gl ass usi ng a sui tabl e sharp col d kni fe. A
pneumati c cutti ng devi ce can be used i f avai l abl e.
Fig. 1 Windshield
SIDE MOLDING SUPPORT SPACER UPPER MOLDING SIDE MOLDINGROOF PANEL SUPPORT SPACER BLOCKER STUD SUPPORT SPACER
WINDSHIELD
ALIGNMENT SPACER
Fig. 2 Cut Urethane Around WindshieldTypical
COLD KNIFE WINDSHIELD
ZG BODY 23 - 5
REMOVAL AND INSTALLATION (Continued)
(2) Separate gl ass from vehi cl e.
INSTALLATION
CAUTION: Open a window before installing glass.
This will avoid pressurizing the passenger compart-
ment. If a door or liftgate is slammed before ure-
thane is cured, water leaks can result.
The wi ndow openi ng fence shoul d be cl eaned of ol d
urethane bondi ng materi al .
(1) Cl ean i nsi de of gl ass wi th Mopar Gl ass Cl eaner
and l i nt-free cl oth.
(2) Appl y PVC (vi nyl ) pri mer 25 mm (1 i n.) wi de
around edge of gl ass. Wi pe wi th cl ean/dry l i nt-free
cl oth.
(3) Appl y fence pri mer around edge of fence. Al l ow
at l east ei ghteen mi nutes dryi ng ti me.
(4) Appl y a 10 mm (0.4 i n.) bead of urethane
around wi ndow vi nyl border l ocati on.
Posi ti on gl ass i nto wi ndow openi ng and l ock cl i ps
i nto pl ace (Fi g. 5).
Fig. 3 Center Windshield and Mark at
SupportSpacers
A-PILLAR WINDSHIELD MARKS SUPPORT SPACER COWL
Fig. 4 Work Surface Set up and Molding Installation
WINDSHIELD AND MOULD- INGS URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM EDGE BLOCKS
Fig. 5 Quarter Window Glass
CLIP ROOF PANEL QUARTER WINDOW GLASS
23 - 6 BODY ZG
REMOVAL AND INSTALLATION (Continued)
LIFTGATE GLASS
REMOVAL
(1) Cut urethane bondi ng from around l i ftgate
gl ass usi ng a sui tabl e sharp col d kni fe. A pneumati c
cutti ng devi ce can be used i f avai l abl e.
(2) Separate gl ass from vehi cl e.
INSTALLATION
CAUTION: Open a window before installing glass.
This will avoid pressurizing the passenger compart-
ment. If a door or liftgate is slammed before ure-
thane is cured, water leaks can result.
The wi ndow openi ng fence shoul d be cl eaned of ol d
urethane bondi ng materi al .
(1) Cl ean i nsi de of gl ass wi th Mopar Gl ass Cl eaner
and l i nt-free cl oth.
(2) Appl y PVC (vi nyl ) pri mer 25 mm (1 i n.) wi de
around edge of gl ass. Wi pe wi th cl ean/dry l i nt-free
cl oth.
(3) Appl y fence pri mer around edge of fence. Al l ow
at l east ei ghteen mi nutes dryi ng ti me.
(4) Appl y a 10 mm (0.4 i n.) bead of urethane
around wi ndow vi nyl border l ocati on.
Posi ti on gl ass i nto wi ndow openi ng and l ock cl i ps
i nto pl ace (Fi g. 6).
Fig. 6 Liftgate Glass
ZG BODY 23 - 7
REMOVAL AND INSTALLATION (Continued)
POWER SUNROOF
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 8
REMOVAL AND INSTALLATION
DRAIN CHANNEL . . . . . . . . . . . . . . . . . . . . . . . 10
DRIVE CABLE LOCATORS . . . . . . . . . . . . . . . . 10
DRIVE CABLES . . . . . . . . . . . . . . . . . . . . . . . . 10
GLASS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GUIDE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 11
MOTOR AND DRIVE GEARS . . . . . . . . . . . . . . 10
SUNROOF ADJUSTMENT BRACKET . . . . . . . . . 8
SUNSHADE . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WIND DEFLECTOR . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING AND INSPECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . 11
ADJUSTMENTS
GLASS PANEL VERTICAL HEIGHT
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 12
GENERAL INFORMATION
GENERAL INFORMATION
Al l sunroofs are equi pped wi th drai n tubes (Fi g. 1)
and (Fi g. 2). The drai n tubes must be kept open to
prevent water from enteri ng passenger compartment.
REMOVAL AND INSTALLATION
WIND DEFLECTOR
REMOVAL
(1) Open sun roof gl ass panel .
(2) Remove screws hol di ng wi nd defl ector to sun
roof uni t si de rai l (Fi g. 3).
(3) Separate wi nd defl ector from vehi cl e.
INSTALLATION
(1) Reverse precedi ng operati on.
GLASS PANEL
REMOVAL
(1) Posi ti on gl ass to vent posi ti on.
(2) Remove wi nd defl ector mechani sm covers (Fi g.
4).
(3) Posi ti on sunshade ful l rearward.
(4) Loosen nuts hol di ng gl ass panel to si de adjust-
ment brackets show i n Vi ew B (Fi g. 4).
(5) Sl i de gl ass panel rearward 12mm (0.5i n.) and
separate gl ass from sunroof uni t.
INSTALLATION
(1) Posi ti on gl ass panel i n openi ng wi th l ogo rear-
ward and sl i de panel forward 12 mm (0.5i n.).
(2) Veri fy that attachi ng nuts are bel ow top sur-
face of gl ass adjustment brackets.
(3) Cl ose sunroof to center gl ass panel i n roof
openi ng.
(4) Ti ghten center nuts to hol d adjustment.
(5) Open gl ass to vent posi ti on and ti ghten nuts to
8 Nm (70.8 i n. l bs.).
(6) Cl ose gl ass and check al i gnment.
(7) Locate gl ass to vent posi ti on.
(8) I nstal l mechani sm covers.
SUNROOF ADJUSTMENT BRACKET
REMOVAL
(1) Remove wi nd defl ector, mechani sm covers and
gl ass panel .
(2) Move gl ass carri age to vent posi ti on and
remove rearward adjustment bol t from adjustment
bracket.
Fig. 1 Drain Tubes
REIN- FORCE- MENT FWDROOF DRAIN TUBE CLAMP DRAIN TUBE DRAIN TUBE CLAMP NUT (8 PLACES) DRAIN TUBE
23 - 8 BODY ZG
(3) Li ft rear of adjustment bracket to hi ghest ver-
ti cal posi ti on and di sengage front of bracket from
uni t (Fi g. 4).
INSTALLATION
(1) Reverse the precedi ng operati on. Adjust gl ass
as necessary.
Fig. 2 Drain Tube Locations
FWD INDEX DRAIN TUBE FWD BODY DRAIN TUBE FWD CLAMP PLUG/ADAPTER
REAR LEFT SIDE SHOWN RIGHT SIDE SIMILAR
Fig. 3 Deflector Assembly
TOP SURFACE OF ROOF PANEL
WIND DEFLECTOR
Fig. 4 Glass Adjustment
VIEW A MECHANISM COVER ADJUSTMENT BRACKET STUD VIEW B GLASS ATTACHMENT NUT ADJUSTMENT BOLTS
ZG BODY 23 - 9
REMOVAL AND INSTALLATION (Continued)
DRAIN CHANNEL
REMOVAL
(1) Move gl ass to vent posi ti on.
(2) Remove mechani sm covers and gl ass panel .
(3) Remove screws hol di ng drai n channel to sup-
port frame.
INSTALLATION
(1) Reverse precedi ng operati on.
DRIVE CABLE LOCATORS
REMOVAL
(1) Posi ti on gl ass 19 mm (0.75 i n.) unti l rearward
cabl e l ocator i s vi si bl e.
(2) Remove screws hol di ng dri ve cabl e l ocator to
uni t.
(3) Remove travel l i mi ti ng mi cro swi tch grommet
and di sconnect wi re connector.
(4) I nsert a smal l screwdri ver under rear edge of
l ocator and pry l ocator from track (Fi g. 5).
INSTALLATION
(1) Reverse precedi ng operati on. The smal l out-
board l i p underneath cabl e l ocator sl i ps under bottom
sl ot on gui de track. After l ocator i s seated, i nstal l
screws.
MOTOR AND DRIVE GEARS
REMOVAL
(1) Open sunroof to vent posi ti on.
(2) Remove headl i ni ng.
(3) Remove bol ts hol di ng sunroof motor to motor
bracket.
(4) Di sconnect wi re connector.
(5) Separate motor and dri ve gear from dri ve
cabl es (Fi g. 6).
INSTALLATION
(1) Veri fy that sunroof i s i n vent posi ti on. Push
mechani sm forward on both si des to al i gn dri ve
cabl es.
(2) Engage dri ve gears onto dri ve cabl es.
(3) I nstal l motor and dri ve gear screws and
ti ghten to 5 Nm (44i n-l bs.).
(4) I nstal l headl i ni ng.
DRIVE CABLES
REMOVAL
(1) Open sunroof to vent posi ti on.
(2) Remove headl i ni ng, wi nd defl ector, mechani sm
covers, gl ass panel , si de gl ass adjustment brackets,
motor and dri ve cabl e l ocators.
(3) Li ft cabl e out of cabl e retai ner and pul l for-
ward. Separate cabl e from assembl y (Fi g. 7).
INSTALLATION
Veri fy sunroof i s i n vent posi ti on. Push mechani sm
forward on both si des to al i gn dri ve cabl es. Reverse
the precedi ng operati on.
Fig. 5 Removing Cable Drive Locator
LOCATOR SCREWDRIVER
Fig. 6 Sunroof Motor And Drive Gear
BOLTS MOTOR BRACKET RETAINER MOTOR ASSEMBLY ELECTRICAL CON- NECTOR BOLT
Fig. 7 Drive Cables
CABLE ASSEMBLY GUIDE ASSEMBLY SCREWDRIVER
23 - 10 BODY ZG
REMOVAL AND INSTALLATION (Continued)
SUNSHADE
REMOVAL
(1) Remove wi nd defl ector, mechani sm covers and
gl ass panel .
(2) Posi ti on system to ful l rearward posi ti on.
(3) Sl i de sunshade panel ful l forward and rel ease
the front tabs from track assembl y.
(4) Pul l front and rear retai ni ng cl i ps i nboard and
l i ft sunshade out (Fi g. 8).
INSTALLATION
(1) Reverse removal procedure.
GUIDE ASSEMBLY
REMOVAL
(1) Remove wi nd defl ector, mechani sm covers,
gl ass panel , drai n channel , sunshade and dri ve cabl e
l ocator as necessary.
(2) Move gl ass carri age to vent posi ti on.
(3) Remove front sl i de from gui de assembl y.
(4) Remove screws hol di ng front and center gui de
track to uni t.
(5) Pul l cabl e out of groove for cabl e end.
(6) Pul l gui de outward to rel ease from housi ng.
Separate rear end of gui de from cl i ps. Sl i de gui de out
of uni t (Fi g. 9).
INSTALLATION
(1) I nstal l gui de cabl e i nto rear of gui de assembl y.
(2) I nstal l gui de assembl y at an angl e so the rear
porti on sl i ps under fi nger cl i ps at rear of modul e
housi ng.
(3) Pl ace cabl e i n groove of cabl e hol der.
(4) I nstal l screws i n track assembl y.
(5) I nstal l wi nd defl ector, mechani sm covers, gl ass
panel , drai n channel , sunshade and dri ve cabl e l oca-
tor as necessary.
CLEANING AND INSPECTION
GENERAL INFORMATION
Al l sunroofs are equi pped wi th drai n tubes (Fi g. 1)
and (Fi g. 2). The drai n tubes must be kept open to
prevent water from enteri ng passenger compartment.
Fig. 8 Sunshade
FRONT TABS RETAINER CLIPS REAR TABS SUNSHADE
Fig. 9 Guide Assembly
GUIDE ASSEMBLY CABLE ASSEMBLY
Fig. 10 Drain Tubes
REIN- FORCE- MENT FWDROOF DRAIN TUBE CLAMP DRAIN TUBE DRAIN TUBE CLAMP NUT (8 PLACES)
DRAIN TUBE
ZG BODY 23 - 11
REMOVAL AND INSTALLATION (Continued)
ADJ USTMENTS
GLASS PANEL VERTICAL HEIGHT ADJUSTMENT
(1) Open gl ass to vent posi ti on.
(2) Sl i de upper hal f of mechani sm covers rearward
unti l cl i ps di sengage and separate covers from vehi -
cl e (Fi g. 12).
(3) Cl ose gl ass panel . Separatel y l oosen adjusti ng
bol ts shown i n Vi ew A (Fi g. 12) and i ndi vi dual l y
adjust the corners of the gl ass.
(4) Adjust front of gl ass panel to 1.0 mm (0.040
i n.) bel ow top surface of roof panel .
(5) Adjust rear of gl ass to 1.0 mm (0.040 i n.) above
top surface of roof panel .
(6) Ti ghten adjustment bol ts and i nstal l covers.
Fig. 12 Glass Adjustment
VIEW A MECHANISM COVER ADJUSTMENT BRACKET STUD VIEW B GLASS ATTACHMENT NUT ADJUSTMENT BOLTS
Fig. 11 Drain Tube Locations
FWD INDEX DRAIN TUBE FWD BODY DRAIN TUBE FWD CLAMP PLUG/ADAPTER REAR LEFT SIDE SHOWN RIGHT SIDE SIMILAR CLAMP SECTION A-A RIGHT SIDE LEFT SIDE BODY RIGHT SIDE FWD DRAIN TUBE BEYOND THIS POINT SAME AS RIGHT SIDE DRAIN TUBE DRAIN TUBE REAR LEFT SIDE SHOWN RIGHT SIDE SIMILAR DRAIN TUBE DRAIN TUBE
23 - 12 BODY ZG
SEATS
INDEX
page page
REMOVAL AND INSTALLATION
BUCKET SEAT BACK COVER . . . . . . . . . . . . . 13
BUCKET SEAT BACK . . . . . . . . . . . . . . . . . . . . 13
BUCKET SEAT CUSHION COVER . . . . . . . . . . 14
BUCKET SEAT TRACK . . . . . . . . . . . . . . . . . . . 14
LUMBAR SUPPORT . . . . . . . . . . . . . . . . . . . . . 13
REAR SEAT BACK COVER . . . . . . . . . . . . . . . 15
REAR SEAT CUSHION COVER . . . . . . . . . . . . 15
REMOVAL AND INSTALLATION
BUCKET SEAT BACK
REMOVAL
(1) Posi ti on seat back i nto ful l recl i ne.
(2) Remove seat cushi on outboard tri m cover.
(3) Remove bol ts attachi ng recl i ner to seat cushi on
frame.
(4) Remove i nboard pi vot bol t.
(5) Di sengage el ectri cal connectors for power l um-
bar, power recl i ner and seat heater el ement, i f
equi pped.
(6) Separate seat back from vehi cl e.
INSTALLATION
(1) Posi ti on seat back i n vehi cl e.
(2) Engage el ectri cal connectors for power l umbar,
power recl i ner and seat heater el ement, i f equi pped.
(3) I nstal l i nboard pi vot bol t. Ti ghten bol t to 40
Nm (29 ft. l bs.) torque.
(4) I nstal l bol ts attachi ng recl i ner to seat cushi on
frame. Ti ghten bol ts to 28 Nm (20 ft. l bs.) torque.
(5) I nstal l seat cushi on outboard tri m cover.
BUCKET SEAT BACK COVER
REMOVAL
(1) Remove head restrai nt.
(2) Remove seat back.
(3) Unfasten seat back cover zi pper.
(4) Route zi pper over power recl i ner motor, i f
equi pped.
(5) Sl i de hand between the face of the seat back
cushi on and the cushi on cover and careful l y separate
hook and l oop fastener (Fi g. 1).
(6) Rol l cover upward to top of seat back.
(7) Careful l y sl i de cover over head restrai nt gui de
sl eeves.
(8) Separate cover from seat back.
INSTALLATION
(1) Posi ti on cover at the top of seat back.
(2) Careful l y sl i de cover over head restrai nt gui de
sl eeves.
(3) Rol l cover downward.
(4) Route zi pper over power recl i ner motor, i f
equi pped.
(5) Fasten seat back cover zi pper.
(6) I nstal l seat back.
(7) I nstal l head restrai nt.
LUMBAR SUPPORT
REMOVAL
(1) Remove seat back.
(2) Remove seat back cover.
(3) Sl i de Duon cover upward to access bol ts
attachi ng recl i ner to seat back frame (Fi g. 2) and
remove recl i ner.
(4) Di sengage hog ri ngs at base of seat back.
(5) Sl i de seat back frame out of seat back foam
cushi on.
(6) Remove Duon cover.
INSTALLATION
(1) Transfer components (Fi g. 3):
Back panel .
Head restrai nt sl eeves.
U-nut on i nboard pi vot l ocati on.
Fig. 1 Seat Back Cover
HEAD RESTRAINT GUIDE SLEEVE SEAT BACK COVER HOOK AND LOOP FAS- TENER SEAT BACK
ZG BODY 23 - 13
(2) I nstal l recl i ner. Ti ghten to 28 Nm (20 ft. l bs.)
torque.
(3) Sl i de on Duon cover.
(4) Sl i de on seat back foam cushi on
(5) I nstal l hog ri ngs at seat back base.
(6) I nstal l seat back cover.
(7) Route l umbar and heater harness, i f equi pped.
BUCKET SEAT CUSHION COVER
REMOVAL
(1) Remove seat from vehi cl e.
(2) Remove seat back.
(3) Usi ng a tri m sti ck, careful l y pry knobs from
seat functi on swi tches, i f equi pped.
(4) Remove screws attachi ng seat functi on swi tch
to seat tri m panel .
(5) Di sengage J-strap attachi ng seat cover to front
of seat cushi on frame.
(6) Usi ng a tri m sti ck or smal l fl at bl ade, di sen-
gage cl i ps attachi ng seat cover to each si de of seat
cushi on frame.
(7) Di sengage hog ri ngs attachi ng seat cover to
rear of seat cushi on frame.
(8) Route seat functi on swi tches through access
hol e on outboard si de of seat cushi on, i f equi pped.
(9) Di sengage seat cushi on heater el ement connec-
tor, i f equi pped.
(10) Sl i de hand between seat cushi on cover and
seat cushi on. Careful l y separate hook and l oop fas-
tener (Fi g. 4).
(11) Separate seat cushi on cover from seat cush-
i on.
INSTALLATION
(1) Posi ti on seat cover on cushi on.
(2) Al i gn seat cover wi th cushi on al i gnment i nden-
tati ons (Fi g. 5).
(3) Engage seat cushi on heater el ement connector,
i f equi pped.
(4) Route seat functi on swi tches through access
hol e on outboard si de of seat cushi on, i f equi pped.
(5) Engage J-strap attachi ng seat cover to front of
seat cushi on frame.
(6) Engage hog ri ngs attachi ng seat cover to rear
of seat cushi on frame.
(7) Engage cl i ps attachi ng seat cover to each si de
of seat cushi on frame.
(8) I nstal l screws attachi ng seat functi on swi tch to
seat tri m panel .
(9) I nstal l seat back.
(10) Posi ti on knobs onto seat functi on swi tches
and press i nto pl ace.
(11) I nstal l seat.
BUCKET SEAT TRACK
REMOVAL
(1) Remove seat.
(2) Remove nuts attachi ng seat track to seat cush-
i on frame.
Fig. 2 Seat Back
SEATBACK DUONCOVER RECLINER SEAT BACK FRAME
Fig. 3 Lumbar Support
HEAD RESTRAINT SLEEVE GUIDE BACK PANEL LUMBAR U-NUT LUMBAR MOTOR
Fig. 4 Seat Cushion Cover
J-STRAP CUSHION COVER SEAT CUSH- ION HOOK AND LOOP FAS- TENER
23 - 14 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(3) Di sengage seat memory modul e connector, i f
equi pped.
(4) Separate seat track from seat cushi on frame.
INSTALLATION
(1) Transfer seat memory modul e, i f equi pped.
(2) Posi ti on seat track on seat cushi on frame.
(3) Engage seat memory modul e connector, i f
equi pped.
(4) I nstal l nuts attachi ng seat track to seat cush-
i on frame. Ti ghten nuts to 20 Nm (15 ft. l bs.) torque.
REAR SEAT BACK COVER
REMOVAL
(1) Remove seatback from vehi cl e. I f necessary,
refer to removal procedure.
(2) Remove headrest. Twi st knob under headrest
and pul l up and out of cyl i nders i n seatback.
(3) Unfasten zi pper (Fi g. 6) on tri m cover. and peel
cover off pad by turni ng i nsi de-out.
(4) I f necessary, headrest cyl i nders may be
removed from seatback frame. Squeeze l ocki ng tabs
on cyl i nder and sl i de cyl i nder upward and remove
from frame bracket.
INSTALLATION
Reverse removal procedure.
REAR SEAT CUSHION COVER
REMOVAL
(1) Remove seat cushi on from vehi cl e. I f necessary,
refer to removal procedure.
(2) Usi ng a tri m tool , di sengage seat cover retai n-
ers that hol d tri m cover to fl ange of cushi on pan.
(3) Remove pad and cover from pan.
(4) Separate cover from pad by turni ng i nsi de-out
and openi ng hogri ngs al ong 3 grooves i n pad.
INSTALLATION
Reverse removal procedure.
Fig. 5 Seat Cushion Alignment Indentations
SEAT CUSHION ALIGNMENT INDENTATIONS HOOK AND LOOP FAS- TENER
Fig. 6 Seatback Cover Removal
COVER
ZG BODY 23 - 15
REMOVAL AND INSTALLATION (Continued)
BODY COMPONENTS
INDEX
page page
DIAGNOSIS AND TESTING
UNIVERSAL TRANSMITTER . . . . . . . . . . . . . . 18
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 17
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE PROCEDURES
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . 18
REMOVAL AND INSTALLATION
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . 33
ASSIST HANDLE . . . . . . . . . . . . . . . . . . . . . . . 33
BODY SIDE CLADDING . . . . . . . . . . . . . . . . . . 32
BODY STRIPES/DECALS . . . . . . . . . . . . . . . . . 21
C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . 35
CARGO CARPET/MAT . . . . . . . . . . . . . . . . . . . 38
COWL GRILLE AND SCREEN . . . . . . . . . . . . . 21
D-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . 35
EXTERIOR NAMEPLATES . . . . . . . . . . . . . . . . 21
FLIP-UP GLASS SWITCH . . . . . . . . . . . . . . . . . 44
FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . 37
FRONT BUCKET SEAT . . . . . . . . . . . . . . . . . . 37
FRONT CARPET/MAT . . . . . . . . . . . . . . . . . . . 38
FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . 25
FRONT DOOR INNER BELT SEAL . . . . . . . . . . 27
FRONT DOOR INSIDE HANDLE ACTUATOR . . 26
FRONT DOOR LATCH STRIKER . . . . . . . . . . . 26
FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . 26
FRONT DOOR LOCK CYLINDER . . . . . . . . . . . 25
FRONT DOOR OPENING WEATHERSTRIP . . . 27
FRONT DOOR OUTER BELT SEAL . . . . . . . . . 27
FRONT DOOR OUTSIDE HANDLE . . . . . . . . . . 25
FRONT DOOR RUN CHANNEL WEATHERSTRIP . 27
FRONT DOOR SCUFF PLATE . . . . . . . . . . . . . 33
FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . 24
FRONT DOOR WATERDAM . . . . . . . . . . . . . . . 24
FRONT DOOR WINDOW GLASS . . . . . . . . . . . 28
FRONT DOOR WINDOW REGULATOR . . . . . . 28
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT FENDER . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT SHOULDER BELT/BUCKLE . . . . . . . . . 36
FUEL DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 32
GRILLE OPENING REINFORCEMENT (GOR) . . 19
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . 20
HOOD LATCH STRIKER . . . . . . . . . . . . . . . . . . 20
HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . 20
HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . 20
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LICENSE PLATE LAMP HOUSING . . . . . . . . . . 45
LIFTGATE FLIP-UP GLASS LATCH HANDLE/
STRIKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LIFTGATE FLIP-UP GLASS LATCH . . . . . . . . . 44
LIFTGATE FLIP-UP GLASS WEATHERSTRIP . . 44
LIFTGATE FLIP-UP GLASS . . . . . . . . . . . . . . . 43
LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . . . 42
LIFTGATE LATCH STRIKER . . . . . . . . . . . . . . . 43
LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . . 42
LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . . 42
LIFTGATE OPENING WEATHERSTRIP . . . . . . 43
LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . . 42
LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . . . 41
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
LOWER B-PILLAR TRIM PANEL . . . . . . . . . . . . 35
LUGGAGE RACK . . . . . . . . . . . . . . . . . . . . . . . 46
LUGGAGE RACKLIMITED PLUS . . . . . . . . . . 46
QUARTER TRIM PANELS . . . . . . . . . . . . . . . . 35
QUARTER WINDOW APPLIQUE/AIR EXHAUSTER . 45
REAR DOOR HINGE . . . . . . . . . . . . . . . . . . . . 29
REAR DOOR INNER BELT SEAL . . . . . . . . . . . 31
REAR DOOR INSIDE HANDLE ACTUATOR . . . 30
REAR DOOR LATCH STRIKER . . . . . . . . . . . . 30
REAR DOOR LATCH . . . . . . . . . . . . . . . . . . . . 30
REAR DOOR OPENING WEATHERSTRIP . . . . 31
REAR DOOR OUTER BELT SEAL . . . . . . . . . . 31
REAR DOOR OUTSIDE HANDLE . . . . . . . . . . . 30
REAR DOOR SCUFF PLATE . . . . . . . . . . . . . . 35
REAR DOOR TRIM PANEL . . . . . . . . . . . . . . . . 28
REAR DOOR WINDOW GLASS . . . . . . . . . . . . 31
REAR DOOR WINDOW REGULATOR . . . . . . . 31
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REAR SEAT CUSHION . . . . . . . . . . . . . . . . . . . 37
REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . 38
REAR SHOULDER/LAP BELT/BUCKLE . . . . . . 36
REARVIEW MIRROR SUPPORT BRACKET . . . 39
REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . 38
SAFETY LATCH STRIKER . . . . . . . . . . . . . . . . 21
SIDE VIEW MIRRORS . . . . . . . . . . . . . . . . . . . 22
SUNVISOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
UPPER B-PILLAR TRIM PANEL . . . . . . . . . . . . 34
ADJUSTMENTS
DOOR LATCH ADJUSTMENT . . . . . . . . . . . . . . 47
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
HOOD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 47
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SPECIFICATIONS
BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . . 48
SPECIAL TOOLS
SPECIAL TOOLSBODY . . . . . . . . . . . . . . . . . 48
23 - 16 BODY ZG
DIAGNOSIS AND TESTING
WATER LEAKS
Water l eaks can be caused by poor seal i ng,
i mproper body component al i gnment, body seam
porosi ty, mi ssi ng pl ugs, or bl ocked drai n hol es. Cen-
tri fugal and gravi tati onal force can cause water to
dri p from a l ocati on away from the actual l eak poi nt,
maki ng l eak detecti on di ffi cul t. Al l body seal i ng
poi nts shoul d be water ti ght i n normal wet-dri vi ng
condi ti ons. Water fl owi ng downward from the front of
the vehi cl e shoul d not enter the passenger or l uggage
compartment. Movi ng seal i ng surfaces wi l l not
al ways seal water ti ght under al l condi ti ons. At
ti mes, si de gl ass or door seal s wi l l al l ow water to
enter the passenger compartment duri ng hi gh pres-
sure washi ng or hard dri vi ng rai n (severe) condi -
ti ons. Overcompensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng
a repai r, water-test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
VISUAL INSPECTION BEFORE WATER LEAK
TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear, and body components are properl y
al i gned and seal ed. I f component al i gnment or seal -
i ng i s necessary, refer to the appropri ate secti on of
thi s group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the condi ti ons causi ng a water l eak have
been determi ned, si mul ate the condi ti ons as cl osel y
as possi bl e.
I f a l eak occurs wi th the vehi cl e parked i n a
steady l i ght rai n, fl ood the l eak area wi th an open-
ended garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds
i n a steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the
spray i n a di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mu-
l ate thi s condi ti on. Thi s method can be used when
the l eak occurs when the vehi cl e accel erates, stops or
turns. I f the l eak occurs on accel erati on, hoi st the
front of the vehi cl e. I f the l eak occurs when braki ng,
hoi st the back of the vehi cl e. I f the l eak occurs on l eft
turns, hoi st the l eft si de of the vehi cl e. I f the l eak
occurs on ri ght turns, hoi st the ri ght si de of the vehi -
cl e. For hoi sti ng recommendati ons refer to Group 0,
Lubri cati on and Mai ntenance, General I nformati on
secti on.
WATER LEAK DETECTION
To detect a water l eak poi nt-of-entry, do a water
test and watch for water tracks or dropl ets formi ng
on the i nsi de of the vehi cl e. I f necessary, remove i nte-
ri or tri m covers or panel s to gai n vi sual access to the
l eak area. I f the hose cannot be posi ti oned wi thout
bei ng hel d, have someone hel p do the water test.
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak
appears, fi nd the hi ghest poi nt of the water track or
drop. The hi ghest poi nt usual l y wi l l show the poi nt of
entry. After l eak poi nt has been found, repai r the
l eak and water test to veri fy that the l eak has
stopped.
Locati ng the entry poi nt of water that i s l eaki ng
i nto a cavi ty between panel s can be di ffi cul t. The
trapped water may spl ash or run from the cavi ty,
often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on an i ncl i ne.
MIRROR INSPECTION METHOD
When a l eak poi nt area i s vi sual l y obstructed, use
a sui tabl e mi rror to gai n vi sual access. A mi rror can
al so be used to defl ect l i ght to a l i mi ted-access area
to assi st i n l ocati ng a l eak poi nt.
BRIGHT LIGHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can
be detected wi thout water testi ng. Posi ti on the vehi -
cl e i n a bri ghtl y l i t area. From i nsi de the darkened
l uggage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the open-
i ng.
PRESSURIZED LEAK TEST METHOD
When a water l eak i nto the passenger compart-
ment cannot be detected by water testi ng, pressuri ze
the passenger compartment and soap test exteri or of
the vehi cl e. To pressuri ze the passenger compart-
ment, cl ose al l doors and wi ndows, start engi ne, and
set heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to ensure adequate vol tage to the bl ower.
Wi th i nteri or pressuri zed, appl y di sh detergent sol u-
ti on to suspected l eak area on the exteri or of the
vehi cl e. Appl y detergent sol uti on wi th spray devi ce or
soft bri stl e brush. I f soap bubbl es occur at a body
seam, joi nt, seal or gasket, the l eak entry poi nt coul d
be at that l ocati on.
ZG BODY 23 - 17
WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai rti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai rti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
crosswi nds. Over compensati ng on door or gl ass
adjustments to stop wi nd noi se that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After a repai r pro-
cedure has been performed, test vehi cl e to veri fy
noi se has stopped before returni ng vehi cl e to use.
Wi nd noi se can al so be caused by i mproperl y fi tted
exteri or mol di ngs or body ornamentati on. Loose
mol di ngs can fl utter, creati ng a buzzi ng or chatteri ng
noi se. An open cavi ty or protrudi ng edge can create a
whi stl i ng or howl i ng noi se. I nspect the exteri or of the
vehi cl e to veri fy that these condi ti ons do not exi st.
VISUAL INSPECTION BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and
body components are al i gned and seal ed. I f compo-
nent al i gnment or seal i ng i s necessary, refer to the
appropri ate secti on of thi s group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Dri ve the vehi cl e to veri fy the general l ocati on
of the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm
(6 i n.) l engths al ong weatherstri ps, wel d seams or
mol di ngs. After each l ength i s appl i ed, dri ve the vehi -
cl e. I f noi se goes away after a pi ece of tape i s appl i ed,
remove tape, l ocate, and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd-rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
UNIVERSAL TRANSMITTER
Uni versal Transmi tter wi l l operate most:
Garage door opener
Gate opener
Home/Offi ce l i ghti ng and/or securi ty system(s)
The transmi tter i s powered by the M1 ci rcui t that
suppl i es vol tage to the dri ver si de vi sor/vani ty l amp.
TRAINING THE UNIVERSAL TRANSMITTER
To trai n the transmi tter refer to the Owners Man-
ual .
TESTING TRANSMITTER
(1) Check for battery vol tage at the Uni versal
Transmi tter by pressi ng a button and seei ng i f a red
l amp comes on. I f OK, go to Step 6. I f not OK, go to
Step 2.
(2) Check i f vi sor/vani ty l amp l i ghts. I f l amp l i ghts,
repl ace vi sor. I f l amp does not l i ght go to Step 3.
(3) Check fuse. I f OK, go to Step 4. I f not OK,
repai r as necessary.
(4) Remove vi sor and test M1 wi re for battery vol t-
age at the vi sor connector. I f vol tage i s OK, go to
Step 5. I f no vol tage repai r wi re as necessary. Refer
to Group 8W, Wi ri ng Di agrams for proper termi nal s.
(5) Test Z1 wi re for ground at the vi sor connector.
I f ground i s OK, repl ace vi sor. I f no ground repai r
wi re as necessary.
(6) Check the i nstructi ons i n the Owners Manual
and retrai n the transmi tter. I f the transmi tter can
not be trai ned repl ace vi sor.
SERVICE PROCEDURES
BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
sengers cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri odi -
cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng):
Spray a smal l amount of l ock cyl i nder l ubri cant
di rectl y i nto the l ock cyl i nder.
Appl y a smal l amount to the key and i nsert i t
i nto the l ock cyl i nder.
Rotate i t to the l ocked posi ti on and then back to
the unl ocked posi ti on several ti mes.
23 - 18 BODY ZG
DIAGNOSIS AND TESTING (Continued)
Remove the key. Wi pe the l ubri cant from i t wi th
a cl ean cl oth to avoi d soi l i ng of cl othi ng.
REMOVAL AND INSTALLATION
GRILLE
REMOVAL
(1) Open hood.
(2) Remove screws attachi ng gri l l e to gri l l e open-
i ng rei nforcement (Fi g. 1).
(3) Separate gri l l e from vehi cl e.
INSTALLATION
(1) Posi ti on gri l l e at gri l l e openi ng panel .
(2) I nstal l screws.
GRILLE OPENING REINFORCEMENT (GOR)
REMOVAL
(1) Open hood.
(2) Remove gri l l e.
(3) Remove front fasci a. Refer to Group 13, Frame
and Bumpers for Removal /I nstal l ati on procedures.
(4) I f equi pped, remove l i cense pl ate bracket from
bumper fasci a/crossmember.
(5) Remove si de marker and turn si gnal l amps.
Refer to Group 8L, for Removal /I nstal l ati on proce-
dures.
(6) Remove headl amps.
(7) Remove bol ts that attach gri l l e openi ng rei n-
forcement (GOR) to the upper and l ower crossmem-
ber (Fi g. 1).
(8) Remove gri l l e openi ng rei nforcement.
(9) I f necessary, remove ai r seal s l ocated at head-
l amp wi ri ng i nl ets (Fi g. 2).
INSTALLATION
For i nstal l ati on, reverse removal procedure.
HOOD
REMOVAL
(1) Rai se hood.
(2) I f equi pped, di sconnect underhood l amp con-
nector.
(3) Mark l ocati on of the hood hi nges and hi nge
shi ms (Fi g. 3) for i nstal l ati on al i gnment.
(4) Remove nuts that attach hi nges to hood.
Remove hood from vehi cl e wi th ai d of a hel per.
Fig. 1 Grille and Grille Opening
Reinforcement(GOR)
HOOD RELEASE CABLE HEADLAMP MOUNTING PANEL GRILLE OPENING REIN- FORCEMENT WITH HEAD- LAMPS GRILLE U-NUT
Fig. 2 GOR Air Seals
GRILLE OPENING REIN- FORCEMENT HEADLAMP BULB AIR SEAL
Fig. 3 Hood Hinge
MOUNTING NUT HINGE MOUNTING NUT
ZG BODY 23 - 19
SERVICE PROCEDURES (Continued)
INSTALLATION
(1) Posi ti on hood on shi ms and hi nges. Fi nger-
ti ghten hi nge nuts.
(2) Al i gn hi nges and shi ms wi th i nstal l ati on refer-
ence marks. Ti ghten hi nge nuts to 23 Nm (17 ft-l bs)
torque.
(3) Test l atch rel ease cabl e and l atches for proper
operati on.
(4) Connect underhood l amp connector.
(5) I nspect hood for proper al i gnment and adjust
as necessary.
HOOD HINGE
(1) Remove hood from vehi cl e.
(2) Remove hi nge retai ni ng nuts from studs (Fi g.
3).
(3) Remove hi nge from i nner cowl si de panel .
INSTALLATION
(1) Posi ti on hi nge over studs.
(2) I nstal l hi nge retai ni ng nuts on studs. Ti ghten
retai ni ng nuts to 23 Nm (17 ft. l bs.) torque.
(3) I nstal l hood.
(4) Adjust hood as necessary. I f necessary, refer to
adjustment procedure.
HOOD LATCH
REMOVAL
(1) Remove nuts that attach l atch to radi ator
crossmember support (Fi g. 4).
(2) Di sconnect l atch from the hood rel ease cabl e.
Remove l atch.
INSTALLATION
(1) Connect l atch to l atch rel ease cabl e. Posi ti on i t
on radi ator crossmember support.
(2) I nstal l nuts. Ti ghten nuts to 11 Nm (8 ft-l bs)
torque.
(3) Test operati on of l atch rel ease cabl e and l atch.
HOOD LATCH STRIKER
REMOVAL
(1) Remove bol ts attachi ng stri ker to hood.
(2) Remove stri ker from hood.
INSTALLATION
(1) Posi ti on stri ker on hood.
(2) I nstal l bol ts. Ti ghten bol ts to 11 Nm (8 ft-l bs)
torque.
(3) Test stri ker/hood al i gnment by openi ng and
cl osi ng hood several ti mes. Adjust stri ker, i f neces-
sary.
HOOD RELEASE CABLE
REMOVAL
(1) Di sconnect cabl e from hood l atch.
(2) Di sconnect cabl e from retai ni ng cl i ps.
(3) Remove l eft cowl si de (ki ck) tri m panel .
(4) Remove cabl e bracket attachi ng screws from
cowl si de panel (Fi g. 5).
(5) Pul l cabl e through dash panel and remove i t
from under i nstrument panel .
Fig. 4 Hood Striker and Release Cable
SECONDARY HOOD CATCH HOOD LATCH STRIKER HOODBUMPER HOOD RELEASE CABLE HOOD LATCH HOODHINGE HOOD
Fig. 5 Hood Release Cable
CABLEBOLT PULL HANDLE CABLE HOUSING
23 - 20 BODY ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nsert repl acement cabl e end through hol e i n
dash panel i nto engi ne compartment.
(2) Pul l cabl e forward and seat grommet i n dash
panel .
(3) Posi ti on cabl e bracket on cowl si de panel and
i nstal l screws. Ti ghten screws to 11 Nm (8 ft-l bs)
torque.
(4) I nstal l l eft cowl si de tri m panel .
(5) Route cabl e i nto retai ni ng cl i ps.
(6) Attach cabl e to hood l atch.
(7) Test rel ease cabl e for proper operati on.
SAFETY LATCH STRIKER
REMOVAL
(1) Remove l atch stri ker screw from hood.
(2) Remove stri ker from hood.
INSTALLATION
(1) Posi ti on stri ker on hood. I nstal l screw.
(2) Test safety l atch operati on.
COWL GRILLE AND SCREEN
REMOVAL
(1) Remove wi per arms. Refer to Group 8K, Wi per
and Washer Systems for Removal /I nstal l ati on proce-
dures.
(2) Remove screws that attach gri l l e to cowl (Fi g.
6).
(3) Remove wi ndshi el d washer tubes from nozzl es.
(4) Remove cowl gri l l e and screen from cowl .
INSTALLATION
(1) Posi ti on cowl gri l l e on cowl . I nstal l wi ndshi el d
washer tubes on nozzl es.
(2) I nstal l cowl gri l l e retai ni ng screws.
(3) I nstal l wi ndshi el d wi per arms.
EXTERIOR NAMEPLATES
Al l of the vehi cl e exteri or namepl ates (Fi g. 7), are
attached to the vehi cl e panel s wi th adhesi ve.
REMOVAL
(1) Usi ng a tri m sti ck or sui tabl e tool , careful l y
pry namepl ate from body panel .
INSTALLATION
(1) Cl ean panel surface.
(2) Posi ti on repl acement namepl ate on panel and
push i nward to seat i t.
BODY STRIPES/DECALS
Body stri pes are durabl e, weather-resi stant tape
stri pes wi th pressure-sensi ti ve backi ng. The tape
stri pe i s protected by a carri er unti l i nstal l ed on a
body panel . Carri er al so i s an i nstal l ati on al i gnment
ai d.
REMOVAL
(1) Remove exteri or tri m as necessary to cl ear cap-
tured edges of tape stri pe bei ng removed
(2) Remove tape stri pe usi ng a sui tabl e heat gun
or l amp. Thi s wi l l soften adhesi ve backi ng.
(3) Cl ean adhesi ve resi due from body fi ni sh usi ng
a sui tabl e adhesi ve remover.
INSTALLATION
The pai nted surface of the body panel to be covered
by a tape stri pe must be smooth and compl etel y
cured before stri pe can be appl i ed. I f pai nted surface
i s not smooth, wet sand wi th 600 gri t wet/dry sand
paper unti l surface i s smooth.
Ri ppl es and feather edges wi l l read through stri pe
i f surface i s not properl y prepared.
I nstal l ati on Equi pment:
Bucket fi l l ed wi th a mi l d di sh soap sol uti on.
Li nt free appl i cator cl oth or sponge.
Body putty appl i cator squeegee.
Heat gun or sun l amp.
Razor kni fe.
(1) Wi th backi ng sti l l i n pl ace, posi ti on stri pe
across panel to recei ve the stri pe. Appl y maski ng at
top of stri pe to hol d i t i n posi ti on.
(2) Mark outsi de edge of panel on stri pe wi th
grease penci l .
(3) Tri m stri pe to wi thi n 17 mm (0.750 i n.) of out-
l i ne marks.
(4) Spread stri pe across a smooth fl at work sur-
face, stri pe si de down.
Fig. 6 Cowl Grille Components
WIPER ARM
WIPER BLADE
COWL COVER SCREW LINKAGE AND PIVOT ASSEMBLY
WASHER HOSE
COWLCOVER
ZG BODY 23 - 21
REMOVAL AND INSTALLATION (Continued)
(5) Peel paper backi ng away from stri pe exposi ng
adhesi ve backi ng of stri pe (Fi g. 8).
(6) Appl y soap sol uti on l i beral l y to adhesi ve back-
i ng of stri pe.
(7) Appl y soap sol uti on to body panel surface.
(8) Pl ace stri pe i nto posi ti on on body panel .
Smooth out wri nkl es by pul l i ng l i ghtl y on edges of
tape stri pe unti l i t l ays fl at on panel surface.
(9) Push ai r pockets from under tape stri pe to
peri meter of panel from center of the tape stri pe out.
(10) Remove ai r bubbl es from under tape stri pe
usi ng a body putty squeegee.
CAUTION: Do nut cut into painted surface of body
when trimming tape stripe to size.
(11) Tri m tape stri pe to si ze usi ng a razor kni fe.
Leave at l east 13 mm (0.5 i n.) for edges of doors and
openi ngs.
CAUTION: Do not overheat tape stripe when per-
forming step 12.
(12) Appl y heat to tape stri pe to evaporate resi d-
ual moi sture from edges of tape stri pe. Thi s wi l l al so
al l ow tape stri pe to be stretched i nto concave sur-
faces.
(13) Edge turn tape stri pe around doors or fenders.
(14) I nstal l exteri or tri m i f necessary. Smal l ai r or
water bubbl es under tape stri pe can be pi erced wi th
a pi n and smoothed out.
SIDE VIEW MIRRORS
REMOVAL
(1) Remove door tri m panel .
(2) Di sengage power mi rror connector from tri m
panel .
Fig. 7 Exterior Nameplates
Fig. 8 Tape Stripe
CARRIER STRIPE TAPE STRIPES
23 - 22 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(3) I f equi pped, di sengage two-way el ectrochromi c
mi rror connector from wi ri ng harness.
(4) Remove cl i ps attachi ng mi rror harness to door
i nner panel .
(5) Remove mi rror fl ag seal .
(6) Remove mi rror retai ni ng nuts (Fi g. 9).
(7) Remove mi rror from door. Refer to Group 8,
El ectri cal for addi ti onal i nformati on i nvol vi ng power
mi rrors.
INSTALLATION
(1) Posi ti on mi rror on door. Veri fy that the O-ri ng
seal and gasket seal are properl y posi ti oned.
(2) I nstal l mi rror retai ni ng nuts.
(3) I nstal l mi rror fl ag seal .
(4) I nstal l cl i ps attachi ng mi rror harness to door
i nner panel .
(5) I f equi pped, engage two-way el ectrochromi c
mi rror connector to wi ri ng harness.
(6) Engage power mi rror connector at tri m panel .
(7) I nstal l door tri m panel .
FRONT FENDER
REMOVAL
(1) Remove headl amp, si de marker and turn si gnal
l amp. Refer to Group 8L, Lamps for servi ce i nforma-
ti on.
(2) Remove front bumper fasci a. Refer to Group
13, Frame and Bumpers for servi ce i nformati on.
(3) Remove front wheel .
(4) Remove fasteners attachi ng i nner front fender
l i ner to fender and i nner fender (Fi g. 10).
(5) Remove i nner fender l i ner.
(6) Ri ght fender onl y:
(a) I f equi pped, remove radi o antenna mast, nut,
pad and base from fender. Refer to group 8F, Audi o
Systems for Removal /I nstal l ati on procedures.
(7) From i nsi de wheel wel l , remove bol ts at rear of
fender rei nforcements (Fi g. 11).
(8) Remove bol ts at front fender bracket (Fi g. 12).
(9) Remove bol ts at l ower rear of fender at A-pi l l ar.
(10) Remove upper mounti ng bol ts at top of fender.
(11) Remove fender from i nner fender.
INSTALLATION
(1) Posi ti on fender on i nner fender panel .
(2) I nstal l al l of fender attachi ng screws fi nger-
ti ght.
(3) Al i gn fender wi th adjacent body panel s.
Ti ghten fender bol ts to 9 Nm (80 i n-l bs) torque.
(4) I nstal l i nner fender l i ner.
(5) I nstal l front wheel .
(6) I nstal l front bumper fasci a. I f necessary refer
to Group 13, Frame and Bumpers for i nstal l ati on
i nstructi ons.
(7) I nstal l front headl amp, si de marker and turn
si gnal l amp. I f necessary refer to Group 8L, Lamps
for servi ce i nformati on.
Fig. 9 Side View Mirror
MIRROR MIRROR FLAG SEAL FWD DOOR
Fig. 10 Inner Fender Liner
FENDER INNER FENDER BUMPER FASCIA INNER FENDER LINER
FASTENERS
Fig. 11 Inner Fender Mounting
FENDER INNER MOUNTING BOLTS (2) FASCIA FASTENER FENDER LINER
ZG BODY 23 - 23
REMOVAL AND INSTALLATION (Continued)
FRONT DOOR TRIM PANEL
REMOVAL
(1) Remove screw attachi ng tri m panel to i nsi de
rel ease handl e (Fi g. 13).
(2) Remove screw at armrest.
(3) Remove screw at the upper mi rror bezel .
(4) Remove the screw i n the tri m panel depressi on.
(5) Usi ng tri m remover (C-4829 or equi val ent),
detach tri m panel peri meter push-i n fasteners from
door i nner panel .
(6) I f equi pped, di sconnect the wi ri ng connectors
from power swi tch panel .
(7) Li ft tri m panel over i nsi de rel ease handl e and
remove tri m panel from door.
INSTALLATION
(1) I f equi pped, connect the wi ri ng connectors to
power swi tch panel .
(2) Posi ti on tri m panel on door i nner panel .
(3) Press push-i n fasteners i nward around peri me-
ter of door to attach i t to i nner panel .
(4) I nstal l armrest screw.
(5) I nstal l mi rror bezel screw.
(6) I nstal l the screw i n the tri m panel depressi on.
(7) I nstal l screw attachi ng tri m panel to i nsi de
rel ease handl e.
FRONT DOOR WATERDAM
REMOVAL
(1) Remove the door tri m panel .
(2) Peel the i nsul ator and waterdam from the door.
(3) Route al l harnesses through waterdam as nec-
essary.
(4) Separate i nsul ator and waterdam from door
(Fi g. 14).
INSTALLATION
(1) Waterdam contact surface must be free of con-
tami nants. Cl ean as necessary.
(2) Route al l harnesses through waterdam as nec-
essary.
(3) Posi ti on waterdam and i nsul ator on door and
al i gn al l hol es.
(4) Press waterdam and i nsul ator on door.
(5) I nstal l the door tri m panel .
FRONT DOOR
REMOVAL
(1) Remove tri m panel .
(2) I f equi pped, di sconnect power wi ndow regul a-
tor, power door l ock motor and al l other wi re harness
connectors.
(3) Sl i de wi re harness out of boot and door
(4) Mark an outl i ne around door hi nges for i nstal -
l ati on al i gnment reference.
(5) Remove door hi nge, retai ni ng bol ts, pl ates and
shi ms (Fi g. 15).
(6) I denti fy and retai n door hi nge pl ates and shi ms
for correct i nstal l ati on.
Fig. 12 Fender Mounting
FENDER UPPER FENDER BOLTS (5) FRONT LOWER FENDER BOLTS (2) LOWER REAR FENDER BOLTS (2)
Fig. 13 Front Door Trim Panel
U-NUT
FRONT DOOR
U-NUT
Fig. 14 Waterdam-Insulator
DOOR
WATER DAM
INSULATOR
23 - 24 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(7) Separate door from vehi cl e.
INSTALLATION
(1) I f a repl acement front door i s bei ng i nstal l ed,
coat door i nteri or wi th anti -corrosi on wax. Al so, seal
door hem fl ange wi th seal ant.
(2) Transfer ori gi nal hardware. I f necessary, refer
to appl i cabl e procedures.
(3) Posi ti on door i n body openi ng.
(4) Al i gn door hi nges, pl ates and shi ms wi th bol t
hol es. I nstal l (but do not ti ghten) hi nge bol ts.
(5) Adjust door to reference marks. I f necessary,
refer to adjustment procedure. Ti ghten hi nge bol ts to
35 Nm (26 ft-l bs) torque.
(6) Adjust l atch stri ker as necessary.
(7) I f appl i cabl e, route and connect harness con-
nectors to door and vehi cl e body wi re harness connec-
tors.
(8) I nstal l door waterdam (i f removed), tri m panel .
FRONT DOOR HINGE
REMOVAL
(1) Open and support door.
(2) Remove bol ts attachi ng hi nge to B-pi l l ar (Fi g.
16).
(3) Separate door from vehi cl e.
INSTALLATION
(1) Support door.
(2) Posi ti on door at B-pi l l ar.
(3) I nstal l bol ts attachi ng hi nge to B-pi l l ar.
Ti ghten outer bol ts to 40 Nm (360 i n. l bs.) and i nner
bol ts 34 Nm (300 i n. l bs.) torque.
FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove door tri m panel and waterdam.
(2) Remove access hol e cover and door handl e
retai ni ng nuts.
(3) Di sconnect handl e l atch rod from l atch (Fi g.
17).
INSTALLATION
(1) Reverse removal procedure.
FRONT DOOR LOCK CYLINDER
REMOVAL
(1) Remove door tri m panel and waterdam. I f nec-
essary. refer to removal procedure.
(2) Di sconnect door l atch l ock cyl i nder rod at door
l atch (Fi g. 17).
(3) I f equi pped, di sconnect securi ty al arm swi tch
connector from l ock cyl i nder (Fi g. 18).
(4) Remove key l ock cyl i nder retai ner cl i p. Remove
l ock cyl i nder, gasket and cl i p from door.
(5) I f appl i cabl e, remove door l atch l ock cyl i nder
rod from ori gi nal l ock cyl i nder. Connect i t to repl ace-
ment l ock cyl i nder.
Fig. 15 Door Hinges and Bolts
UPPER HINGE MOUNTING BOLTS LOWER HINGE
Fig. 16 Front Door Hinge
UPPER HINGE MOUNTING BOLTS LOWER HINGE
Fig. 17 Front Door Outside Handle
DOOR HAN- DLE DOOR LOCK LOCK RETAINER LATCH LATCH SCREW ACCESS PLUG OUTSIDE HANDLE LATCH ROD
ZG BODY 23 - 25
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Reverse removal procedure.
FRONT DOOR LATCH
REMOVAL
(1) Remove door tri m panel and waterdam.
(2) Remove door l atch retai ni ng screws (Fi g. 19).
(3) Di sconnect al l rods from door l atch (Fi g. 20).
(4) Di sconnect wi re connector, i f equi pped.
(5) Remove door l atch from door.
INSTALLATION
(1) Reverse removal procedure. Ti ghten l atch
screws to 10 Nm (95 i n. l bs.) torque.
FRONT DOOR LATCH STRIKER
REMOVAL
(1) Remove screws attachi ng stri ker to B-pi l l ar.
(2) Separate stri ker from B-pi l l ar.
INSTALLATION
(1) Posi ti on stri ker on B-pi l l ar.
(2) I nstal l screws attachi ng stri ker to B-pi l l ar.
Ti ghten screws to 5 Nm (45 i n. l bs.) torque.
FRONT DOOR INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove door tri m panel and waterdam. I f nec-
essary, refer to removal procedure.
(2) Remove door i nsi de l atch rel ease handl e screws
(Fi g. 21).
(3) Move door rel ease handl e outward. Di sconnect
handl e l atch and l ock rods.
(4) Remove door i nsi de handl e actuator from door.
Fig. 18 Security Alarm Switch
SECURITY ALARM SWITCH FRONT DOOR LOCK CYLINDER SECURITY ALARMSWITCH SERRATED RETAINER DOOR INNER PANEL WIRE HARNESS CONNECTOR
Fig. 19 Door Latch Removal
ACCESS HOLE DOOR
LATCH MOUNTING
BOLTS
LATCH
Fig. 20 Door Latch
OUTSIDE HANDLE LATCH ROD
INSIDE RELEASE LATCH ROD
Fig. 21 Front Door Inside Handle Actuator
HANDLE AND LOCK ASSEM- BLY DOOR LOCK AND LATCH RODS
23 - 26 BODY ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Reverse removal procedure.
FRONT DOOR INNER BELT SEAL
REMOVAL
(1) Remove door tri m panel .
(2) Usi ng a tri m sti ck, careful l y pry rear i nner
edge of seal upward.
(3) Grasp seal and pul l upward to separate from
door fl ange (Fi g. 22).
INSTALLATION
(1) Posi ti on seal on door fl ange.
(2) Fi rml y press downward to seat seal on fl ange.
(3) I nstal l tri m panel .
FRONT DOOR OUTER BELT SEAL
REMOVAL
(1) Lower wi ndow gl ass.
(2) Remove screw from i nner door panel attachi ng
seal to outer door panel (Fi g. 23).
(3) Grasp seal and pul l rearward to rel ease i t from
si de vi ew mi rror bezel .
(4) Li ft seal upward and separate from door.
INSTALLATION
(1) Li ghtl y l ubri cate the front of the seal
(2) Posi ti on the seal onto the door fl ange.
(3) Sl i de the front of the seal behi nd the si de vi ew
mi rror bezel . Force the seal onto door fl ange. Con-
ti nue rearward unti l i t i s seated on fl ange.
(4) I nstal l the screw securi ng the seal to the outer
door panel .
FRONT DOOR RUN CHANNEL WEATHERSTRIP
REMOVAL
(1) Lower wi ndow gl ass.
(2) Grasp seal from upper run channel corner and
fi rml y separate weatherstri p from fl ange (Fi g. 24).
INSTALLATION
NOTE: Soapy water may be used to aid in installa-
tion.
(1) Posi ti on weatherstri p on fl ange al i gni ng
notches i n each corner.
(2) Press weatherstri p i nto posi ti on.
FRONT DOOR OPENING WEATHERSTRIP
REMOVAL
(1) Remove A-pi l l ar tri m panel .
(2) Remove B-pi l l ar upper tri m panel .
(3) Remove B-pi l l ar l ower tri m panel .
(4) Grasp seal and separate from door openi ng.
Fig. 22 Front Door Inner Belt Seal
FRONT DOOR INNER BELT SEAL FRONT DOOR OUTER BELT SEAL FRONT DOOR
Fig. 23 Front Door Outer Belt Seal
OUTER BELT SEAL
FRONT DOOR
Fig. 24 Front Door Glass Run Channel Weatherstrip
DOOR GLASS RUN CHANNEL WEATHER- STRIP FRONT DOOR
ZG BODY 23 - 27
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on weatherstri p at corners usi ng pai nt
dots as al i gnment poi nts.
(2) Move upward and around edge of door openi ng.
Seat seal on fl ange (Fi g. 25).
(3) Engage connector pl ug wi th each end of weath-
erstri p at bottom of door openi ng.
(4) I nstal l B-pi l l ar l ower tri m panel .
(5) I nstal l B-pi l l ar upper tri m panel .
(6) I nstal l A-pi l l ar tri m panel .
FRONT DOOR WINDOW REGULATOR
REMOVAL
(1) Remove door tri m panel and waterdam. I f nec-
essary, refer to removal procedure.
(2) Posi ti on wi ndow gl ass to access wi ndow track
nuts (Fi g. 26).
(3) Loosen wi ndow track nuts and sl i de track off of
the wi ndow.
(4) Remove wi ndow regul ator retai ni ng screws
(Fi g. 27).
(5) Li ft wi ndow upward and separate i t from reg-
ul ator. Support wi ndow.
(6) Remove wi ndow regul ator from door.
INSTALLATION
(1) Reverse removal procedure.
FRONT DOOR WINDOW GLASS
REMOVAL
(1) Remove door tri m panel and waterdam. I f nec-
essary, refer to removal procedure.
(2) Remove bel tl i ne mol di ng and weatherstri p
seal s.
(3) Remove wi ndow track retai ni ng nuts.
(4) Li ft wi ndow gl ass upward and out of door.
INSTALLATION
(1) Lower wi ndow gl ass i nto posi ti on.
(2) I nstal l wi ndow track retai ni ng nuts.
(3) I nstal l bel tl i ne mol di ng and weatherstri p seal s.
(4) I nstal l door tri m panel and waterdam.
REAR DOOR TRIM PANEL
REMOVAL
(1) Remove screw attachi ng tri m panel to i nsi de
rel ease handl e (Fi g. 28).
(2) Remove screw at armrest.
(3) Usi ng tri m remover (C-4829 or equi val ent),
detach tri m panel peri meter push-i n fasteners from
door i nner panel .
(4) I f equi pped, di sconnect the wi ri ng connectors
from power swi tch panel .
(5) Li ft tri m panel over i nsi de rel ease handl e and
remove tri m panel from door.
INSTALLATION
(1) I f equi pped, connect the wi ri ng connectors to
power swi tch panel .
(2) Posi ti on tri m panel on door i nner panel .
(3) Press push-i n fasteners i nward around peri me-
ter of door to attach i t to i nner panel .
Fig. 25
FRONT DOOR
SEAL
INDEXMARKS REAR DOOR SEAL CONNECTORPLUG
Fig. 26 Front Door Window Track
LOOSEN 2 NUTS SLIDE
Fig. 27 Front Door Window Regulator
LOOSEN ONLY CHANNEL ATTACHING SCREWS REGULATOR SCREWS LOOSEN ONLY
23 - 28 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(4) I nstal l armrest screw.
(5) I nstal l mi rror bezel screw.
(6) I nstal l screw attachi ng tri m panel to i nsi de
rel ease handl e.
REAR DOOR
REMOVAL
(1) Remove door tri m panel .
(2) Di sconnect power wi ndow regul ator, power door
l ock motor and al l other wi re harness connectors.
(3) Sl i de wi re harness out of boot and door.
(4) Mark an outl i ne around door hi nges for i nstal -
l ati on al i gnment reference.
(5) Remove door hi nge, retai ni ng bol ts, pl ates and
shi ms (Fi g. 29). Remove door from vehi cl e.
(6) I denti fy and retai n door hi nge pl ates and shi ms
for correct i nstal l ati on.
INSTALLATION
(1) I f a repl acement front door i s bei ng i nstal l ed,
coat door i nteri or wi th anti -corrosi on wax. Al so, seal
door hem fl ange wi th seal ant.
(2) Before i nstal l i ng a repl acement door, transfer
ori gi nal hardware. I f necessary, refer to appl i cabl e
procedures.
(3) Posi ti on door i n body openi ng.
(4) Al i gn door hi nges, pl ates and shi ms wi th bol t
hol es. I nstal l (but do not ti ghten) hi nge bol ts.
(5) Adjust door to reference marks. I f necessary,
refer to adjustment procedure. Ti ghten hi nge bol ts to
28 Nm (250 i n. l bs.) torque.
(6) Adjust l atch stri ker as necessary.
(7) I f appl i cabl e, route and connect harness con-
nectors to door and vehi cl e body wi re harness connec-
tors.
(8) I nstal l door waterdam (i f removed), tri m panel ,
armrest and wi ndow gl ass regul ator handl e.
REAR DOOR HINGE
REMOVAL
(1) Open and support door.
(2) Remove bol ts attachi ng hi nge to C-pi l l ar (Fi g.
30).
(3) Separate door from vehi cl e.
Fig. 28 Rear Door Trim Panel
REAR DOOR U-NUT TRIM PANEL PLUG BEZEL FWD
Fig. 29 Rear Door
DOOR LATCH TO OUTSIDE HANDLE ROD INSIDE RELEASE TO LATCH ROD LOWER RUN CHANNEL REGULATOR PLUG LOWER HINGE UPPER HINGE GLASS CLIP
Fig. 30 Rear Door Hinge
HINGE B-PILLAR
ZG BODY 23 - 29
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Support door.
(2) Posi ti on door at C-pi l l ar.
(3) I nstal l bol ts attachi ng hi nge to C-pi l l ar.
Ti ghten outer bol ts to 40 Nm (360 i n. l bs.) and i nner
bol ts 34 Nm (300 i n. l bs.) torque.
REAR DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove door tri m panel and waterdam. I f nec-
essary, refer to removal /i nstal l ati on procedure.
(2) Remove access hol e cover and door handl e
retai ni ng nuts (Fi g. 31).
(3) Di sconnect handl e l atch rod from l atch.
INSTALLATION
(1) Reverse removal procedure.
REAR DOOR LATCH
REMOVAL
(1) Remove door tri m panel and waterdam. I f nec-
essary, refer to removal procedure.
(2) Remove door l atch retai ni ng screws (Fi g. 31).
(3) Di sconnect al l rods from door l atch.
(4) Remove door l atch from door.
INSTALLATION
(1) Reverse removal procedure.
REAR DOOR LATCH STRIKER
REMOVAL
(1) Open door.
(2) Remove screws attachi ng stri ker to C-pi l l ar
(Fi g. 32).
(3) Separate stri ker and spacer from vehi cl e.
INSTALLATION
(1) Posi ti on stri ker and spacer on C-pi l l ar.
(2) I nstal l screws. Ti ghten to 28 Nm (250 i n. l bs.)
torque.
REAR DOOR INSIDE HANDLE ACTUATOR
REMOVAL
(1) Remove door tri m panel and waterdam.
(2) Remove door i nsi de handl e actuator screws
(Fi g. 33).
(3) Move actuator handl e outward. Di sconnect
handl e l atch and l ock rods.
(4) Remove door i nsi de rel ease handl e from door.
INSTALLATION
Reverse removal procedure.
Fig. 31 Rear Door Outside Handle
ACCESS HOLE INSIDE RELEASE TO LATCH ROD INSIDE LOCK TO LATCH ROD HANDLE LATCH ROD LATCH ADJUSTMENT SCREW REAR DOOR
Fig. 32 Rear Door Latch Striker
C-PILLAR TAPPING PLATE RETAINER STRIKER SPACER FWD
Fig. 33 Rear Door Inside Latch Release Handle
HANDLE AND LOCK ASSEM- BLY DOOR LOCK AND LATCH RODS
23 - 30 BODY ZG
REMOVAL AND INSTALLATION (Continued)
REAR DOOR INNER BELT SEAL
REMOVAL
(1) Remove door tri m panel .
(2) Usi ng a tri m sti ck, careful l y pry rear i nner
edge of seal upward.
(3) Grasp seal and pul l upward to separate from
door fl ange (Fi g. 34).
INSTALLATION
(1) Posi ti on seal on door fl ange.
(2) Fi rml y press downward to seat seal on fl ange.
(3) I nstal l tri m panel .
REAR DOOR OUTER BELT SEAL
REMOVAL
(1) Lower wi ndow gl ass.
(2) Remove screw from i nner door panel attachi ng
seal to outer door panel (Fi g. 35).
(3) Li ft seal upward and separate from door.
INSTALLATION
(1) Posi ti on the seal onto the door fl ange.
(2) Tuck outer bel t seal i ng l i ps i nsi de gl ass run
channel and around di vi si on bar.
(3) Force the seal onto door fl ange. Conti nue rear-
ward unti l i t i s seated on fl ange.
(4) I nstal l the screw securi ng the seal to the outer
door panel .
REAR DOOR OPENING WEATHERSTRIP
REMOVAL
(1) Remove C-pi l l ar tri m panel .
(2) Remove B-pi l l ar upper tri m panel .
(3) Remove B-pi l l ar l ower tri m panel .
(4) Remove screws at the front of the quarter tri m
panel .
(5) Grasp seal and separate from door openi ng.
INSTALLATION
(1) Posi ti on weatherstri p at corners usi ng pai nt
dots as al i gnment poi nts.
(2) Move upward and around edge of door openi ng.
Seat seal on fl ange (Fi g. 25).
(3) Engage connector pl ug wi th each end of weath-
erstri p at bottom of door openi ng.
(4) I nstal l screws at the front of the quarter tri m
panel .
(5) I nstal l B-pi l l ar l ower tri m panel .
(6) I nstal l B-pi l l ar upper tri m panel .
(7) I nstal l C-pi l l ar tri m panel .
REAR DOOR WINDOW REGULATOR
REMOVAL
(1) Remove door tri m panel and waterdam. I f nec-
essary, refer to removal procedure.
(2) Posi ti on wi ndow gl ass to access wi ndow track
nuts (Fi g. 36).
(3) Loosen wi ndow track nuts and sl i de track off of
wi ndow.
(4) Remove wi ndow regul ator retai ni ng screws
(Fi g. 37).
(5) Li ft wi ndow upward and separate i t from reg-
ul ator. Support wi ndow.
(6) Remove wi ndow regul ator from door.
INSTALLATION
(1) Reverse removal procedure.
REAR DOOR WINDOW GLASS
REMOVAL
(1) Lower wi ndow gl ass.
(2) Remove tri m panel and waterdam from door
i nner panel . I f necessary, refer to removal procedure.
Fig. 34 Rear Door Inner Belt Seal
REAR DOOR INNER BELT SEAL REAR DOOR OUTER BELT SEAL REAR DOOR
Fig. 35 Rear Door Outer Belt Seal
OUTER BELT SEAL DOOR
ZG BODY 23 - 31
REMOVAL AND INSTALLATION (Continued)
(3) Pry wi ndow bel tl i ne mol di ng from fl ange.
Remove mol di ng from door.
(4) Remove wi ndow weatherstri p seal s from door.
(5) Remove wi ndow track nuts and sl i de track off
of wi ndow.
(6) Remove di vi si on bar upper attachi ng screw and
bel t l i ne screw (Fi g. 38).
(7) Ti l t stati onary gl ass channel assembl y forward
and remove i t from door.
(8) Remove wi ndow gl ass from door.
INSTALLATION
(1) I nstal l wi ndow gl ass i n door.
(2) Ti ghten gl ass track nuts to 6 Nm (53 i n-l bs)
torque.
(3) I nstal l stati onary gl ass channel i n door.
(4) I nstal l stati onary gl ass channel screws.
Ti ghten screw to 6 Nm (5 ft-l bs) torque.
(5) I nstal l wi ndow gl ass channel and bel t weather-
stri p seal s.
(6) I nstal l wi ndow bel tl i ne mol di ng.
(7) I nstal l door waterdam and tri m panel . I f neces-
sary, refer to i nstal l ati on procedure.
FUEL DOOR
REMOVAL
(1) Open fuel door.
(2) Remove rear quarter tri m panel .
(3) Remove screw attachi ng fuel door to body panel
(Fi g. 39).
(4) Separate fuel door from vehi cl e.
INSTALLATION
(1) Posi ti on fuel door at vehi cl e.
(2) I nstal l screw attachi ng fuel door to body panel .
(3) I nstal l rear quarter tri m panel .
(4) Cl ose fuel door.
BODY SIDE CLADDING
REMOVALFRONT DOOR
(1) Usi ng a tri m sti ck, gentl y l i ft up from bottom
of cl addi ng. Unsnap mol di ng from retai ni ng cl i ps
(Fi g. 40).
Fig. 36 Rear Door Window Track
LOOSEN 2 NUTS SLIDE
Fig. 37 Rear Door Window Regulator
LOOSEN
ONLY
LOOSEN ONLY CHANNEL ATTACH- ING SCREW REGULATOR SCREWS
Fig. 38 Glass Channel
DOOR CHANNEL SCREW
Fig. 39 Fuel Door
FUEL DOOR BODY PANEL BUMPER FWD
23 - 32 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(2) Li ft upward and remove mol di ng.
INSTALLATIONFRONT DOOR
(1) Repl ace al l retai ni ng cl i ps.
(2) I nstal l mol di ng over top of retai ni ng cl i ps.
(3) Al i gn mol di ng to door edges.
(4) Snap mol di ng down over retai ni ng cl i ps.
REMOVALREAR DOOR
(1) Open rear door.
(2) Remove acorn nut at rear dogl eg (Fi g. 40).
(3) Usi ng a tri m sti ck, gentl y l i ft up from bottom
of cl addi ng. Unsnap mol di ng from retai ni ng cl i ps.
INSTALLATIONREAR DOOR
(1) Repl ace al l retai ni ng cl i ps.
(2) I nstal l mol di ng retai ner i nto hol e at dogl eg.
(3) I nstal l mol di ng over top of retai ni ng cl i ps.
(4) Snap mol di ng down over top of retai ni ng cl i ps.
(5) I nstal l acorn nut onto retai ner.
REMOVALFENDER/QUARTER PANEL
(1) Remove screws at wheel openi ng.
(2) Usi ng a tri m sti ck, Gentl y pry upward from
bottom of cl addi ng.
(3) Unsnap cl addi ng from retai ners.
INSTALLATIONFENDER/QUARTER PANEL
(1) Repl ace al l retai ni ng cl i ps.
(2) I nstal l mol di ng over top of retai ner cl i ps.
(3) Snap mol di ng down over retai ni ng cl i ps.
(4) I nstal l screws i nto wheel openi ng.
A-PILLAR TRIM
REMOVAL
(1) Usi ng a tri m sti ck, careful l y pry A-pi l l ar tri m
from A-pi l l ar (Fi g. 41).
INSTALLATION
(1) Posi ti on A-pi l l ar tri m panel at A-pi l l ar and
snap i nto pl ace.
(2) Ensure that the A-pi l l ar covers the i nner edge
of the door openi ng weatherstri p.
ASSIST HANDLE
REMOVAL
(1) Remove the screws attachi ng the handl e to the
headl i ner (Fi g. 42).
(2) Remove assi st handl e from roof panel .
INSTALLATION
(1) Posi ti on handl e on the roof panel .
(2) I nstal l the screws. Ti ghten screws to 3 Nm (22
i n-l bs) torque.
FRONT DOOR SCUFF PLATE
REMOVAL
The front door scuff pl ate i s attached wi th mol d-
ed-i n snap retai ners.
(1) Usi ng a tri m sti ck or si mi l ar tool , careful l y pry
scuff pl ate from si l l . Detach scuff pl ate from si l l (Fi g.
43).
Fig. 40 Body Side Cladding
UPPER HANGER RAIL STUD SILL MOLDING CLADDING RETAINER CLADDING
ZG BODY 23 - 33
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Posi ti on scuff pl ate on si l l and snap i nto pl ace.
UPPER B-PILLAR TRIM PANEL
REMOVAL
(1) Remove the A-pi l l ar tri m panel .
(2) Remove front seat bel t turni ng l oop.
(3) Detach and remove upper B-pi l l ar tri m panel .
INSTALLATION
(1) Posi ti on tri m panel on B-pi l l ar.
(2) Ensure the tri p panel covers the i nner edge of
the door openi ng weatherstri p.
(3) I nstal l front seat bel t turni ng l oop.
(4) I nstal l the A-pi l l ar tri m panel .
Fig. 41 Trim Panels
BODY B-PILLAR UPPER TRIM C-PILLAR TRIM D-PILLAR TRIM PANEL QUARTER TRIM PANEL B-PILLAR LOWER TRIM COWL TRIM A-PILLAR TRIM PANEL
Fig. 42 Assist Handle
MOUNTING SCREW HEADLINER FRONT ASSIST HANDLE
Fig. 43 Scuff Plates
REAR DOOR SCUFF PLATE FRONT DOOR SCUFF PLATE
23 - 34 BODY ZG
REMOVAL AND INSTALLATION (Continued)
LOWER B-PILLAR TRIM PANEL
REMOVAL
(1) Remove the A-pi l l ar tri m panel .
(2) Remove upper B-pi l l ar tri m panel .
(3) Remove screws attachi ng l ower B-pi l l ar tri m
panel to B-pi l l ar (Fi g. 44).
(4) Remove screws attachi ng cowl tri m panel .
(5) Separate l ower B-pi l l ar tri m panel from B-pi l -
l ar.
(6) Route seat/shoul der bel t through access sl ot i n
l ower B-pi l l ar tri m panel .
(7) Remove l ower B-pi l l ar tri m panel (Fi g. 41).
INSTALLATION
(1) Posi ti on l ower B-pi l l ar tri m panel on vehi cl e.
(2) Route seat/shoul der bel t through access sl ot i n
l ower B-pi l l ar tri m panel .
(3) I nstal l screws that attach l ower B-pi l l ar tri m
panel to B-pi l l ar.
(4) I nstal l screws attachi ng cowl tri m panel .
(5) Sl i de upper B-pi l l ar tri m panel downward i nto
pl ace.
(6) I nstal l the A-pi l l ar tri m panel .
REAR DOOR SCUFF PLATE
REMOVAL
The rear door scuff pl ate i s attached wi th mol d-
ed-i n snap retai ners.
(1) Usi ng a tri m sti ck or si mi l ar tool , careful l y pry
scuff pl ate from si l l . Detach scuff pl ate from si l l (Fi g.
43).
INSTALLATION
(1) Posi ti on scuff pl ate on si l l and snap i nto pl ace.
C-PILLAR TRIM
REMOVAL
(1) Remove rear seat bel t turni ng l oop.
(2) Usi ng a tri m sti ck, careful l y pry C-pi l l ar tri m
panel from vehi cl e (Fi g. 41).
INSTALLATION
(1) Posi ti on C-pi l l ar tri m panel on C-pi l l ar. Ensure
the adjustabl e turni ng l oop i s al i gned wi th the tri m
panel sl i der and snap i nto pl ace.
(2) I nstal l rear seat bel t turni ng l oop.
QUARTER TRIM PANELS
(1) Pul l rear seat bottom forward and fol d down
rear seat.
(2) Remove l ower retai ni ng screw at rear door
openi ng (Fi g. 41).
(3) I f equi pped, remove sunshade cover.
(4) Remove C-pi l l ar tri m panel .
(5) Remove screws retai ni ng upper l i ftgate openi ng
tri m panel .
(6) Di sconnect wi ri ng to cargo l amp.
(7) Remove l ower l i ftgate openi ng tri m panel .
(8) Remove D-pi l l ar upper tri m panel .
(9) Remove quarter tri m panel mounti ng screws.
(10) I f necessary, remove spare ti re and ti re stand-
offs from l eft quarter tri m panel (Fi g. 45).
(11) Remove rear quarter tri m panel .
INSTALLATION
(1) Reverse removal procedure.
D-PILLAR TRIM
REMOVAL
(1) Remove l i ftgate openi ng upper tri m panel (Fi g.
46).
(2) Detach and remove tri m panel from D-pi l l ar
(Fi g. 41).
INSTALLATION
(1) Posi ti on D-pi l l ar tri m panel on D-pi l l ar and
snap i n pl ace.
(2) I nstal l upper l i ftgate openi ng tri m panel .
Fig. 44 B-Pillar Trim Panel
MOUNTING SCREWS MOUNTING SCREWS LOWER TRIM PANEL
Fig. 45 Tire Stand-OffsLeft QuarterTrim Panel
COVER TIRE WING NUT RETAINER STUD BUMPER
ZG BODY 23 - 35
REMOVAL AND INSTALLATION (Continued)
FRONT SHOULDER BELT/BUCKLE
REMOVALBUCKLE
(1) Sl i de front seats al l the way forward for access
to buckl e anchor bol t.
(2) Remove anchor bol t cover.
(3) Remove buckl e anchor bol t.
(4) Remove shoul der bel t buckl e from transmi ssi on
tunnel .
INSTALLATIONBUCKLE
(1) Posi ti on seat bel t buckl e i n posi ti on and anchor
bol t.
(2) I nstal l anchor bol t cover.
REMOVALSHOULDER BELT
(1) Unsnap turni ng l oop cover.
(2) Remove upper anchor bol t (Fi g. 47).
(3) Remove B-pi l l ar tri m panel s.
(4) Remove bol t attachi ng retractor to B-pi l l ar.
(5) Remove bol t attachi ng bel t anchor to B-pi l l ar.
(6) Di sconnect retractor wi re hareness connector.
(7) Remove shoul der bel t and retractor.
INSTALLATIONSHOULDER BELT
(1) Reverse removal procedure. Ti ghten anchor
bol ts to 37 Nm (27 ft-l bs)
REAR SHOULDER/LAP BELT/BUCKLE
REMOVALLAP BELT/BUCKLE
(1) Pul l rear seat rel ease l oop and ti l t seat bottom
forward. Remove seat bottom from l ower l atch.
(2) Unl atch seat back and ti l t forward.
(3) Remove shoul der bel t buckl e and l ap bel t/
buckl e anchor pl ate bol ts from the fl oor panel (Fi g.
48).
INSTALLATIONLAP BELT/BUCKLE
(1) Posi ti on shoul der bel t buckl e and l ap bel t/
buckl e on the fl oor panel .
(2) I nstal l bol ts attachi ng l ap bel t/buckl e to fl oor
panel . Ti ghten anchor bol ts to 37 Nm (27 ft-l bs).
Fig. 46 Liftgate Opening Trim Panels
UPPER LIFTGATE OPENING TRIM PANEL LOWER LIFTGATE OPENING TRIM PANEL
Fig. 47 Front Shoulder Belt
SEAT BELT ADJUSTER B-PILLAR TRIM RELEASE BUTTON TURNING LOOP COVER TURNINGLOOP ANCHOR RETRACTOR SHIELD COVER
B-PILLAR
Fig. 48 Rear Seat Shoulder/Lap Belts &Buckles
SEAT BELT ADJUSTERRELEASE BUT- TON TURNING LOOP COVER TURNING LOOP SHOULDER BUCK- LES LAP BUCKLE RETRACTOR C-PILLAR C-PILLARTRIM
23 - 36 BODY ZG
REMOVAL AND INSTALLATION (Continued)
REMOVALSHOULDER BELT
(1) Unsnap turni ng l oop cover.
(2) Remove turni ng l oop anchor bol t (Fi g. 48).
(3) Remove C-pi l l ar and quarter tri m panel .
(4) Remove bel t retractor anchor bol t from rear
quarter rai l .
(5) Remove retractor and shoul der bel t from panel .
INSTALLATIONSHOULDER BELT
(1) Posi ti on retractor and shoul der bel t on panel .
(2) I nstal l bel t retractor anchor bol t i n rear quar-
ter rai l . Ti ghten anchor bol ts to 37 Nm (27 ft-l bs).
(3) I nstal l C-pi l l ar and quarter tri m panel .
(4) I nstal l turni ng l oop anchor bol t. Ti ghten
anchor bol t to 37 Nm (27 ft-l bs).
(5) I nstal l turni ng l oop cover.
FRONT BUCKET SEAT
REMOVAL
(1) Remove bol ts attachi ng seat to fl oor pan (Fi g.
49).
(2) I f equi pped, di sconnect power seat wi re har-
ness connector.
(3) Remove seat from fl oor panel .
INSTALLATION
(1) Posi ti on seat on fl oor pan.
(2) I f equi pped, connect power seat wi re harness
connector.
(3) I nstal l bol ts attachi ng seat to fl oor pan.
Ti ghten front bol ts to 27 Nm (20 ft. l bs.) torque,
ti ghten rear bol ts to 27 Nm (20 ft. l bs.) torque..
FLOOR CONSOLE
REMOVAL
(1) Pul l transmi ssi on shi ft l ever handl e strai ght up
and remove handl e.
(2) Remove transmi ssi on and transfer case shi ft
i ndi cator bezel s by pryi ng upward to rel ease them.
Posi ti on fl at screwdri ver between bezel and consol e
to remove i ndi cator bezel (Fi g. 50).
(3) Di sconnect l amp sockets from bezel s.
(4) Remove consol e retai ni ng screws.
(5) Remove consol e from fl oor.
INSTALLATION
(1) Reverse removal procedure.
REAR SEAT CUSHION
REMOVAL
(1) Di sengage seat cushi on at rear by pul l i ng
upward on rel ease strap.
(2) Ti l t cushi on forward.
(3) Di sengage seat cushi on by pul l i ng upward and
out.
(4) Remove seat cushi on from vehi cl e.
INSTALLATION
(1) Posi ti on seat cushi on i n vehi cl e.
(2) I nsert hi nge i nto l ower pi vot.
(3) Push downward to engage hi nge i nto pi vot.
(4) Rotate cushi on downward i nto seati ng posi ti on.
(5) Lock seat cushi on down by pressi ng fi rml y on
center of cushi on unti l l atch engages.
Fig. 49 Front Bucket Seat
SEAT SIDE- SHIELD SEATFWD
SCREWS
FLOORPAN SEAT TRACK COVER
Fig. 50 Console Components
SHIFTER INDICATOR TRANSFER CASE SHIFTER BEZEL TRANSFER CASE SHIFTER INDICATOR PARKING BRAKE BEZEL FULL FLOOR CONSOLE PARKING BRAKE CONSOLE BRACKET
ZG BODY 23 - 37
REMOVAL AND INSTALLATION (Continued)
REAR SEATBACK
REMOVAL
(1) Remove l ower seat cushi on. Refer to removal
procedure.
(2) Remove bol ts hol di ng seatback si de support
brackets (l eft si de) (Fi g. 51).
(3) Ti l t seatback forward, and sl i de i t outboard to
detach i t from pi n on center pi vot bracket.
(4) Remove l eft si de (60%) seatback from vehi cl e.
(5) Remove bol ts hol di ng seatback si de support
brackets (ri ght si de) (Fi g. 51).
(6) Remove ri ght si de (40%) seatback from vehi cl e.
INSTALLATION
(1) Posi ti on ri ght si de (40%) seatback i n vehi cl e.
(2) Posi ti on ri ght si de support brackets wi th bol t
hol es al i gned and i nstal l support bracket bol ts.
Ti ghten bol ts to 27 Nm (20 ft. l bs.) torque.
(3) Posi ti on l eft si de (60%) seatback i n vehi cl e.
(4) I nstal l seatback onto center pi vot bracket pi n.
Ensure seat back i s properl y engaged on the center
pi vot pi n.
(5) Posi ti on l eft si de support brackets wi th bol t
hol es al i gned and i nstal l support bracket bol ts.
Ti ghten bol ts to 27 Nm (20 ft. l bs.) torque.
(6) I nstal l l ower seat cushi on. Refer to i nstal l ati on
procedure.
FRONT CARPET/MAT
REMOVAL
(1) Remove l ower B-pi l l ar tri m panel s.
(2) Remove front and rear seats (as appl i cabl e).
(3) As necessary, remove tri m panel s and mol d-
i ngs.
(4) Remove fl oor consol e.
(5) Remove al l other i nterferi ng components.
(6) Remove carpet and mat from fl oor panel (Fi g.
52).
INSTALLATION
(1) Reverse removal procedure.
CARGO CARPET/MAT
REMOVAL
(1) Remove quarter tri m panel s.
(2) Remove l i ftgate tri m panel .
(3) Dri l l -out retai ni ng ri vet heads and remove
cargo ti e-down footman l oops from carpet (Fi g. 53).
(4) Remove rear seats and bel ts.
(5) Remove al l other i nterferi ng components.
(6) Remove carpet and mat from fl oor panel (Fi g.
54).
(7) I f necessary, remove ski d stri ps from carpet.
INSTALLATION
(1) Reverse removal procedure.
REARVIEW MIRROR
REMOVAL
(1) I f equi pped, di sconnect mi rror harness wi re
connector.
(2) Loosen the mi rror base setscrew (Fi g. 55) and
(Fi g. 56).
(3) Sl i de the mi rror base upward and off the
bracket.
INSTALLATION
(1) Posi ti on the mi rror base at the bracket and
sl i de i t downward onto the support bracket.
(2) Ti ghten the setscrew 1 Nm (15 i n. l bs.) torque.
Fig. 51 Rear Seat Mounting
REAR SEATBACK CENTER PIVOT BRACKET MOUNTING BOLT REAR SEAT BOT- TOM SIDE SUP- PORTBRACKET
Fig. 52 Front Carpet and Mat
SEAT MOUNT
HOLES
SHIFTER HOLE
SEAT BELT MOUNT HOLES PARKING BRAKE HOLE SEAT MOUNT HOLES SEAT BELT MOUNT HOLES
CARPET
23 - 38 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(3) I f equi pped, connect mi rror harness wi re con-
nector.
REARVIEW MIRROR SUPPORT BRACKET
INSTALLATION
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
Crush the vi al to saturate the fel t appl i cator.
Remove the paper sl eeve.
Appl y accel erator to the contact surface on the
bracket.
Al l ow the accel erator to dry for fi ve mi nutes.
Do not touch the bracket contact surface after
the accel erator has been appl i ed.
(5) Appl y adhesi ve accel erator to the bracket con-
tact surface on the wi ndshi el d gl ass. Al l ow the accel -
erator to dry for one mi nute. Do not touch the gl ass
contact surface after the accel erator has been
appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
Appl y one drop of adhesi ve at the center of the
bracket contact-surface on the wi ndshi el d gl ass.
Appl y an even coat of adhesi ve to the contact
surface on the bracket.
Al i gn the bracket wi th the marked posi ti on on
the wi ndshi el d gl ass.
Fig. 53 Cargo Tie-Down Footman Loop
BLIND RIVET FOOTMAN LOOP SPACER CARPET INSULATION RIVET CROSS SILL FLOOR PANEL FOOTMAN LOOP
NYLON SPACER
Fig. 54 Cargo Carpet & Mat
CARPETING
SEAT BELT MOUNT HOLES
Fig. 55 Rearview Mirror
REARVIEW MIR- ROR WINDSHIELD GLASS SUPPORT BRACKET SCREW
Fig. 56 Rearview Mirror
WINDSHIELD COVER MIRROR SUPPORT
ZG BODY 23 - 39
REMOVAL AND INSTALLATION (Continued)
Press and hol d the bracket i n pl ace for at l east
one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
SUNVISOR
REMOVAL
(1) Remove screws that attach sunvi sor arm sup-
port bracket to headl i ner and roof panel (Fi g. 57).
(2) Detach sunvi sor from support bracket.
(3) Remove sunvi sor from vehi cl e.
(4) Remove retai ni ng screw and support bracket.
INSTALLATION
(1) Reverse removal procedure.
HEADLINER
REMOVAL
CAUTION: The headliner is a one-piece, molded
component. It has limited flexibility and must not be
bent. Damage possibly will result.
(1) Remove the A, B and C-pi l l ar tri m mol di ngs
from peri meter of headl i ner.
(2) I f equi pped, remove sound bar. Refer to group
8F, Audi o Systems for Servi ce procedures.
(3) Remove upper l i ftgate tri m mol di ng.
(4) Remove D-pi l l ar tri m mol di ng.
(5) Remove sunvi sors from front of roof panel . Di s-
connect vani ty l amp wi ri ng (i f appl i cabl e)
(6) Remove assi st handl es from si de of roof rai l s.
(7) Remove push pl ugs from roof support (Fi g. 58).
(8) Remove dome/readi ng l amp or overhead consol e
from center of roof panel .
(9) Remove sunroof pi nch wel t hol di ng headl i ner, i f
equi pped (Fi g. 59).
(10) Wi th ai d of an assi stant, remove headl i ner
through l i ftgate openi ng.
INSTALLATION
(1) Wi th the ai d of an assi stant, posi ti on headl i ner
i n vehi cl e.
(2) I nstal l sunroof pi nch wel t.
(3) I nstal l dome/readi ng l amp.
(4) I nstal l push pl ugs i n roof support.
(5) I nstal l sunvi sors.
Fig. 57 Sunvisor
SUN VISOR MOUNTING OVERHEAD CON- SOLE SUN VISOR VANITY MIRROR
Fig. 58 Headliner
ROOF PANEL ROOF BOW HEADLINER COVER ASSIST HAN- DLE ASSIST HAN- DLE
Fig. 59 Sunroof Opening
PINCH WELT ROOF PANEL FWD RETAINER SUNROOF OPENING
23 - 40 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(6) I nstal l assi st handl es.
(7) I nstal l A, B, C and D-pi l l ar tri m panel s.
(8) I nstal l l i ftgate openi ng upper tri m panel .
(9) I f equi pped, i nstal l sound bar.
LIFTGATE TRIM PANEL
NOTE:
When removing both trim panels from liftgate,
remove lower trim panel first. When installing both
trim panels, install the upper trim panel first.
UPPER TRIM PANEL REMOVAL
(1) Remove screws attachi ng upper tri m panel to
l i ftgate (Fi g. 60).
(2) Remove screws at upper and l ower tri m panel
overl ap.
(3) Di sengage the connector for the rear wi ndow
defogger.
(4) Route the wi re harness through the tri m panel .
(5) Gentl y, pul l tri m panel downward. I f necessary
rotate tri m panel away from gl ass panel to rel ease
push-i n fasteners.
(6) Use a tri m panel removal tool to detach
push-i n fasteners from l i ftgate.
UPPER TRIM PANEL INSTALLATION
(1) Posi ti on tri m panel at l i ftgate and sl i de over-
l appi ng porti ons of tri m panel under l i ftgate l ower
tri m panel .
(2) Route the wi re harness through the tri m panel .
(3) Al i gn tri m panel push-i n fasteners wi th hol es
i n l i ftgate i nner panel . Press tri m panel upward to
seat fasteners.
(4) Engage the connector for the rear wi ndow
defogger.
(5) I nstal l screws at upper and l ower tri m panel
overl ap.
(6) I nstal l screws attachi ng upper tri m panel to
l i ftgate.
LOWER TRIM PANEL REMOVAL
(1) Remove screws attachi ng l ower tri m panel to
l i ftgate (Fi g. 60).
(2) Use a tri m panel removal tool to detach
push-i n fasteners from l i ftgate.
LOWER TRIM PANEL INSTALLATION
(1) Posi ti on tri m panel on l i ftgate.
(2) Al i gn tri m panel push-i n fasteners wi th hol es
i n l i ftgate i nner panel . Press tri m panel i nward to
seat fasteners.
(3) I nstal l screws attachi ng l ower tri m panel to
l i ftgate.
LIFTGATE
REMOVAL
WARNING: DO NOT DISCONNECT THE SUPPORT
ROD CYLINDERS WITH THE LIFTGATE CLOSED.
THE SUPPORT ROD PISTONS ARE OPERATED BY
HIGH PRESSURE GAS. THIS PRESSURE COULD
CAUSE DAMAGE AND/OR PERSONAL INJURY IF
THEY ARE REMOVED WHILE THE PISTONS ARE
COMPRESSED.
(1) Open l i ftgate. Support l i ftgate for ease of
repai r.
(2) Remove l i ftgate tri m panel .
(3) Remove retai ner cl i ps that secure support rod
cyl i nders to bal l studs (Fi g. 61).
(4) Remove support rod cyl i nders from bal l studs.
(5) Remove upper support rod retai ni ng screws.
Remove support rods.
(6) Di sconnect wi re harnesses and washer hose
from l i ftgate.
(7) Remove hi nge screws at l i ftgate (Fi g. 62).
(8) Remove l i ftgate from vehi cl e.
INSTALLATION
(1) Posi ti on l i ftgate on vehi cl e. Support l i ftgate.
(2) I nstal l hi nge screws at l i ftgate. Ti ghten hi nge
screws to 28 Nm (21 ft-l bs) torque
(3) Connect l i ftgate wi re harnesses and washer
hose.
(4) I nstal l upper support rod retai ni ng screws.
(5) I nstal l support rod cyl i nders on bal l studs.
(6) I nstal l l i ftgate tri m panel .
Fig. 60 Liftgate Trim Panel
UPPER TRIM PANEL LIFTGATE LOWER TRIMPANEL
ZG BODY 23 - 41
REMOVAL AND INSTALLATION (Continued)
LIFTGATE HINGE
REMOVAL
I t i s not necessary to remove l i ftgate to repl ace one
or both hi nges. The hi nges can be repl aced one at a
ti me.
(1) Remove l i ftgate openi ng (headl i ner) upper tri m
mol di ng.
(2) Di sconnect wi ri ng harness to cargo l amp.
(3) Remove hi nge screws at roof panel (Fi g. 63).
(4) Remove hi nge screws at l i ftgate.
(5) Remove hi nge from l i ftgate.
INSTALLATION
(1) Posi ti on hi nge on l i ftgate and roof panel . (Use
3M Fast and Fi rm or equi val ent on the hi nge to
body mati ng surface as a seal ant).
(2) I nstal l and ti ghten hi nge screws at roof panel
to 28 Nm (21 ft-l bs) torque.
(3) I nstal l hi nge screws at l i ftgate. Ti ghten screws
to 28 Nm (21 ft-l bs) torque.
(4) I nstal l l i ftgate openi ng (headl i ner) upper tri m
mol di ng.
LIFTGATE OUTSIDE HANDLE
REMOVAL
(1) Remove l i ftgate l ower tri m panel .
(2) Remove l i ftgate l atch and actuator l i nkages.
(3) Remove nuts attachi ng outsi de handl e to l i ft-
gate (Fi g. 64).
(4) Separate outsi de handl e from l i ftgate.
INSTALLATION
(1) Posi ti on outsi de handl e on l i ftgate.
(2) I nstal l nuts attachi ng outsi de handl e to l i ft-
gate.
(3) I nstal l l i ftgate l atch and actuator l i nkages.
(4) I nstal l l i ftgate l ower tri m panel .
LIFTGATE LOCK CYLINDER
For servi ce, refer to the Li ftgate Outsi de Handl e
Removal /I nstal l ati on procedure i n thi s group.
LIFTGATE LATCH
REMOVAL
(1) Rai se l i ftgate. Remove l i ftgate l ower tri m
panel . I f necessary refer to servi ce procedure.
(2) Remove l atch screws (Fi g. 64).
(3) Di sconnect rod from l atch.
(4) Di sconnect power l ock connector from handl e, i f
equi pped (Fi g. 65).
(5) Remove l atch from l i ftgate.
INSTALLATION
(1) Reverse removal procedure. Ti ghten l atch
screws to 7 Nm (5 ft. l bs.) torque.
Fig. 61 Liftgate Prop Rod
BODY FWD LIFTGATE PROP ROD CLIP WASHER BALL STUD
Fig. 62 Liftgate Components
LIFTGATE BUMPER HANDLE LATCH POWER LOCK ACTUATOR UPPERHINGES
Fig. 63 Liftgate Components
LIFTGATE BUMPER HANDLE LATCH POWER LOCK ACTUATOR UPPERHINGES
23 - 42 BODY ZG
REMOVAL AND INSTALLATION (Continued)
LIFTGATE LATCH STRIKER
REMOVAL
(1) Rai se l i ftgate.
(2) Remove l atch stri ker nuts from bel ow scuff
pl ate. Access nuts from under bumper fasci a/beam
(Fi g. 66).
(3) Remove stri ker, shi m and seal pl ate.
INSTALLATION
(1) Posi ti on stri ker, shi m and seal pl ate on vehi cl e.
(2) I nstal l l atch stri ker nuts. Ti ghten stri ker nuts
to 54 Nm (40 ft. l bs.) torque.
LIFTGATE OPENING WEATHERSTRIP
REMOVAL
(1) Pul l seal away from fl ange around edge of l i ft-
gate openi ng. Remove i t from vehi cl e.
(2) Cl ean seal fl ange as necessary.
INSTALLATION
(1) Posi ti on weatherstri p seal i n openi ng wi th l eft
end of seal at openi ng centerl i ne. I nstal l seal i n a
cl ockwi se di recti on.
(2) Seat i nstal l ed part of seal . Move from l eft bot-
tom end of seal to top l eft hal f of the seal .
(3) Center and butt seal ends together at center-
l i ne.
(4) I f necessary, cut surpl us from weatherstri p
(non-pl ug end onl y).
LIFTGATE FLIP-UP GLASS
REMOVAL
WARNING: DO NOT DISCONNECT THE PROP ROD
CYLINDERS WITH THE LIFTGATE FLIP-UP GLASS
CLOSED. THE PROP ROD PISTONS ARE OPER-
ATED BY HIGH PRESSURE GAS. THIS PRESSURE
COULD CAUSE DAMAGE AND/OR PERSONAL
INJURY IF THEY ARE REMOVED WHILE THE PIS-
TONS ARE COMPRESSED.
(1) Remove l i ftgate upper tri m panel .
(2) Open l i ftgate fl i p-up gl ass. Support gl ass for
ease of repai r.
(3) Usi ng a smal l fl at bl ade or equi val ent tool , gen-
tl y pry open the l ocki ng caps on the end of the prop
rod.
(4) Remove prop rod cyl i nders from bal l studs (Fi g.
67).
(5) Remove hi nge nuts from l i ftgate (Fi g. 68).
(6) Separate fl i p-up gl ass from vehi cl e.
INSTALLATION
(1) Posi ti on fl i p-up gl ass on l i ftgate.
(2) I nstal l hi nge nuts. Hand ti ghten onl y.
(3) Wi th the gl ass panel i n the open and ful l y
rai sed posi ti on, push gl ass forward to compl etel y seat
the hi nges. Ti ghten hi nge nuts to 6 Nm (60 i n. l bs.).
(4) I nstal l prop rods onto bal l studs and compress
l ocki ng caps to l ock prop rods onto bal l studs.
Fig. 64 Liftgate Latch/Lock Component
LOCK RETAIN- ING CLIP HANDLE POWER LOCK ACTUATOR
LOCK ROD
HANDLE HANDLE LATCH ROD LATCH LOCK
Fig. 65 Power Lock
HANDLE CONNECTOR
Fig. 66 Liftgate Latch Striker
STRIKER SHIM SEAL PLATE
ZG BODY 23 - 43
REMOVAL AND INSTALLATION (Continued)
FLIP-UP GLASS SWITCH
REMOVAL
(1) Remove l i ftgate tri m panel .
(2) Remove l i cense pl ate l amp housi ng nuts from
l i ftgate.
(3) Squeeze swi tch l ocki ng tabs i nward to rel ease
swi tch from l i cense pl ate l amp housi ng.
(4) Di sconnect swi tch harness connector.
(5) Separate swi tch from housi ng (Fi g. 69).
INSTALLATION
(1) Posi ti on swi tch i nto l i cense pl ate l amp housi ng
and connect swi tch harness connector.
(2) Snap swi tch i nto pl ace.
(3) I nstal l l i cense pl ate l amp housi ng.
(4) I nstal l l i ftgate tri m panel .
LIFTGATE FLIP-UP GLASS WEATHERSTRIP
REMOVAL
(1) Sl owl y pul l seal away from fl ange around edge
of gl ass openi ng. Remove i t from vehi cl e.
(2) Cl ean seal fl ange as necessary.
INSTALLATION
(1) Posi ti on weatherstri p seal wi th pai nt dots
al i gned wi th wi ndow openi ng corners.
(2) Seat seal fi rml y around enti re l i ftgate (Fi g. 70).
(3) Butt seal ends together and smooth out any
remai ni ng l ength. Weathersrti p break shoul d be 120
mm l eft of l atch openi ng.
(4) I f necessary, cut surpl us from weatherstri p
(non-pl ug end onl y).
LIFTGATE FLIP-UP GLASS LATCH
REMOVAL
(1) Rai se l i ftgate.
(2) Remove l i ftgate l ower tri m panel .
Fig. 67 Prop Rod
BALL STUD STRIKER FLIP-UP GLASS LIFTGATE PROP ROD
Fig. 68 Hinge Removal
FLIP-UP GLASS ROOF HINGE FWD LIFTGATE
Fig. 69 Switch Removal
BUMPER BUMPER LICENSE PLATE LAMP HOUSING LIFTGATE
SWITCH
Fig. 70 Liftgate Seal
SEALSEAL LIFTGATE
23 - 44 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(3) Remove l atch nuts (Fi g. 71).
(4) Di sconnect swi tch connectors.
(5) Remove l atch from l i ftgate.
INSTALLATION
(1) Posi ti on l atch on vehi cl e, 2.5 mm forward of
seal .
(2) Connect swi tch connectors.
(3) I nstal l l atch nuts. Ti ghten to 11 Nm (100 i n.
l bs.).
(4) Cl ose fl i p-up gl ass panel and veri fy proper
operati on.
(5) I nstal l l i ftgate l ower tri m panel .
LIFTGATE FLIP-UP GLASS LATCH HANDLE/
STRIKER
REMOVAL
(1) Rai se fl i p-up gl ass.
(2) Usi ng a wax penci l or equi val ent, make al i gn-
ment marks on the i nsi de and outsi de of the gl ass
panel .
(3) Remove handl e/stri ker.
INSTALLATION
(1) Posi ti on handl e/stri ker on gl ass panel and al i gn
reference marks.
(2) I nstal l handl e/stri ker. Ti ghten screws to 6 Nm
(60 i n. l bs.).
LICENSE PLATE LAMP HOUSING
REMOVAL
(1) Remove l i ftgate tri m panel
(2) Remove l amp housi ng retai ni ng screws from
l i ftgate (Fi g. 72).
(3) Di sconnect bul b socket from l amp housi ng.
(4) Di sconnect Fl i p-Up gl ass swi tch connector, i f
equi pped.
(5) Remove housi ng from l i ftgate.
INSTALLATION
(1) Posi ti on l amp housi ng at l i ftgate.
(2) Connect bul b socket to l amp housi ng.
(3) Connect Fl i p-Up gl ass swi tch connector, i f
equi pped.
(4) I nstal l l amp housi ng retai ni ng screws i n l i ft-
gate. Ti ghten screws securel y.
(5) I nstal l l i ftgate tri m panel .
QUARTER WINDOW APPLIQUE/AIR EXHAUSTER
REMOVAL
(1) Usi ng a tri m sti ck, careful l y pry appl i que from
panel (Fi g. 73).
(2) Careful l y pry ai r exhauster from upper quarter
panel usi ng a fl at bl ade screwdri ver.
INSTALLATION
(1) Reseal ai r exhauster usi ng foam tape.
(2) I nstal l ai r exhauster on panel .
(3) Posi ti on appl i que on panel wi th retai ners
al i gned. Press appl i que fi rml y i n pl ace.
Fig. 71 Flip-Up Glass Latch
LATCH AND SWITCH NUT FWD REINFORCE- MENT REAR WIPER MOTOR
Fig. 72 License Plate Lamp Housing
LICENSE PLATE LAMPS FLIP-UP GLASS SWITCH LAMP HOUSING
Fig. 73 Quarter Window Applique & AirExhauster
RETAINING CLIP EXHAUSTER APPLIQUE QUARTER WINDOW
ZG BODY 23 - 45
REMOVAL AND INSTALLATION (Continued)
LUGGAGE RACK
REMOVAL
(1) Remove sl i de rai l screws (Fi g. 74).
(2) Remove l uggage rack from vehi cl e roof.
NOTE: The skid strips are attached to roof panel
with adhesive.
(3) Loosen each ski d stri p wi th a heat gun.
(4) Li ft one edge of each ski d stri p wi th a putty
kni fe and peel i t from roof panel . Appl y addi ti onal
heat to any l ocati on where a ski d stri p remai ns.
(5) Remove ori gi nal adhesi ve from roof panel wi th
an al l - purpose adhesi ve removal sol uti on.
INSTALLATION
(1) I nstal l 3M 06379 doubl e-si ded tape on ski d
stri ps.
(2) Al i gn each ski d stri p on roof panel .
(3) Veri fy that each ski d stri p i s properl y al i gned.
(4) Press each ski d stri p onto roof panel wi th a
rol l er.
NOTE: Apply 3M Drip-Chek Sealant (or an equiva-
lent product) to underside of side rail screw heads.
(5) Posi ti on l uggage rack on roof.
(6) I nstal l and ti ghten sl i de rai l screws to 3 Nm
(28 i n- l bs) torque.
LUGGAGE RACK LIMITED PLUS
REMOVAL
(1) Usi ng a smal l fl at bl ade, careful l y pry off ri ser
cover (Fi g. 75).
(2) I f necessary, depress the l ock buttons on the
crossbars and sl i de crossbars i nward to expose the
screws attachi ng the si de rai l s to the ri sers and
adapter pl ates (Fi g. 76).
(3) Remove the screws attachi ng the si de rai l s to
the ri sers and adapter pl ates (Fi g. 77).
(4) Separate the l uggage rack from the adapter
pl ates.
(5) Remove the screws attachi ng the adapter
pl ates to the roof panel .
NOTE: If a crossbar needs to be removed, the for-
ward or rearward risers have to be removed
depending on which crossbar is to be serviced.
(6) Separate the adapter pl ates from the roof
panel .
INSTALLATION
(1) Posi ti on the adapter pl ates on the roof panel
and i nstal l the screws. Ensure that the gasket i s
properl y seated on the adapter pl ates.
(2) Posi ti on the l uggage rack on the adapter
pl ates.
(3) I nstal l the screws attachi ng the si de rai l s to
the ri sers and adapter pl ates.
Fig. 74 Luggage Rack
CROSS RAIL
SUNROOF STOP
END CAP
Fig. 75 Riser Cover
RISER COVER
Fig. 76 Crossbar Lock Button
FWD
SIDE RAIL
CROSS RAIL
23 - 46 BODY ZG
REMOVAL AND INSTALLATION (Continued)
(4) Posi ti on the ri ser covers on the ri sers and press
i nto pl ace.
ADJ USTMENTS
HOOD ADJUSTMENT
The hood attachi ng hol es are enl arged to ai d front,
back and si de-to-si de adjustment.
(1) I f hood i s l ow i n rel ati on to cowl panel , i nsert
shi ms between hi nge and hood.
(2) Adjust hood bumper (Fi g. 78) i n or out to
adjust hood-to-fender hei ght al i gnment.
(3) Adjust the hood l atch as necessary. Ti ghten the
nuts to 11 Nm (8 ft-l bs) torque after adjustment.
(4) Al i gn l atch stri ker so that stri ker enters the
l atch squarel y and wi thout bi ndi ng.
DOOR
Mi nor adjustment for al i gnment of the door i s
made by movi ng the l atch stri ker.
IN AND OUT
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker i nward i f the door charac-
ter l i ne i s outboard of the body character l i ne or tap
the l atch stri ker outward i f the door character l i ne i s
i nboard of the body character l i ne.
(3) I nspect al i gnment. I f correct, ti ghten stri ker
wi th 28 Nm (21 ft. l bs.) torque.
UP AND DOWN
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker downward i f the door
character l i ne i s hi gher than the body character l i ne
or tap the l atch stri ker upward i f the door character
l i ne i s l ower than the body character l i ne.
(3) I nspect al i gnment. I f correct, ti ghten stri ker
wi th 28 Nm (21 ft. l bs.) torque.
DOOR LATCH ADJUSTMENT
(1) Locate access hol e (Fi g. 79).
(2) I nsert a 5/32-i nch hex-wrench through hol e and
i nto adjustment screw. Loosen screw.
(3) Operate outsi de handl e button several ti mes to
rel ease any restri cti on because of mi s-al i gnment.
(4) Ti ghten adjustment screw to 3 Nm (30 i n-l bs)
torque.
(5) Test handl e button and l ock cyl i nder for proper
operati on.
LIFTGATE
The posi ti on of l i ftgate can be adjusted upward or
downward by use of sl ots i n the hi nge. An i nward or
outward adjustment i s achi eved by use of sl ots i n the
body. I f an i nward or outward adjustment i s needed,
use 3M Fast and Fi rm or equi val ent on the hi nge
to body mati ng surface as a seal ant.
Fig. 77 Siderail
ROOF PANEL SIDE RAIL ADAPTER RISER
Fig. 78 Hood Bumper
HOOD BUMPER GOR
Fig. 79 Door Latch Adjustment
BOLTS
ZG BODY 23 - 47
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
BODY LUBRICANTS
SPECIAL TOOLS
SPECIAL TOOLS BODY
COMPONENT SERVICE INTERVAL LUBRICANT
Door Hinges As Required Engine Oil
Door Latches As Required Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Hood Latch, Release Mechanism and
Safety Latch
As Required
(When Performing Other
Underhood Service)
Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Hood Hinges As Required Engine Oil
Seat Track and Release Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Liftgate Hinge As Required Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Liftgate Support Arms As Required Engine Oil
Liftgate Latches As Required White Spray Lubricant (3)
Liftgate Release Handle (Pivot and Slide
Contact Surfaces)
As Required Multi-Purpose Grease NLGI GC-LB 2
EP (2)
Window System Components As Required White Spray Lubricant (3)
Lock Cylinders Twice a Year Lock-Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2
EP (1)
1 = Mopar Wheel Bearing Grease (High
Temp)
2 = Mopar Multi-Mileage Lubricant
3 = Mopar Spray White Lube
4 = Mopar Lock Cylinder Lubricant
Remover, Moldings C-4829
23 - 48 BODY ZG
HEATING AND AIR CONDITIONING
CONTENTS
page page
GENERAL INFORMATION
HEATER AND AIR CONDITIONER CONTROLS . 2
HEATER AND AIR CONDITIONER . . . . . . . . . . . 2
SERVICE WARNINGS AND PRECAUTIONS . . . . 3
DESCRIPTION AND OPERATION
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . 5
AMBIENT TEMPERATURE SENSOR . . . . . . . . . 5
BLOWER MOTOR POWER MODULE . . . . . . . . . 5
BLOWER MOTOR RESISTOR . . . . . . . . . . . . . . 6
BLOWER MOTOR SWITCH . . . . . . . . . . . . . . . . 6
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 5
COMPRESSOR CLUTCH RELAY . . . . . . . . . . . . 7
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . . . . 6
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . 7
FIXED ORIFICE TUBE . . . . . . . . . . . . . . . . . . . . 7
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . 8
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . . 8
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . . 8
HIGH SPEED BLOWER MOTOR RELAY . . . . . . 8
IN-VEHICLE TEMPERATURE SENSOR . . . . . . . 8
LOW PRESSURE CYCLING CLUTCH SWITCH . 8
REFRIGERANT LINE COUPLER . . . . . . . . . . . . 9
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . . . . 9
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . . . . 9
REFRIGERANT SYSTEM SERVICE
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REFRIGERANT SYSTEM SERVICE PORTS . . . 10
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . 9
SOLAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . 10
VACUUM CHECK VALVE . . . . . . . . . . . . . . . . . 10
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING
A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . . 10
ATC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 16
BLOWER MOTOR RESISTOR . . . . . . . . . . . . . 25
BLOWER MOTOR SWITCH . . . . . . . . . . . . . . . 25
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . 25
COMPRESSOR CLUTCH COIL . . . . . . . . . . . . 26
COMPRESSOR CLUTCH RELAY . . . . . . . . . . . 26
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 25
HEATER PERFORMANCE . . . . . . . . . . . . . . . . 14
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . 27
HIGH SPEED BLOWER MOTOR RELAY . . . . . 27
LOW PRESSURE CYCLING CLUTCH
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REFRIGERANT SYSTEM LEAKS . . . . . . . . . . . 28
VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE PROCEDURES
REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . . 30
REFRIGERANT RECOVERY . . . . . . . . . . . . . . 28
REFRIGERANT SYSTEM CHARGE . . . . . . . . . 29
REFRIGERANT SYSTEM EVACUATE . . . . . . . . 28
REMOVAL AND INSTALLATION
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . 39
AMBIENT TEMPERATURE SENSOR . . . . . . . . 39
BLOWER MOTOR RESISTOR AND POWER
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . 42
COMPRESSOR CLUTCH RELAY . . . . . . . . . . . 36
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . . . 32
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 31
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DUCTS AND OUTLETS . . . . . . . . . . . . . . . . . . 44
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . 48
FIXED ORIFICE TUBE . . . . . . . . . . . . . . . . . . . 39
HEAT/DEFROST AND PANEL/DEFROST DOOR
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
HEAT/DEFROST DOOR ACTUATOR . . . . . . . . 48
HEAT/DEFROST DOOR . . . . . . . . . . . . . . . . . . 49
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . 47
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . . . 40
HEATER-A/C HOUSING . . . . . . . . . . . . . . . . . . 46
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . 36
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . 37
HIGH SPEED BLOWER MOTOR RELAY . . . . . 43
IN-VEHICLE TEMPERATURE SENSOR . . . . . . 41
LOW PRESSURE CYCLING CLUTCH
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PANEL/DEFROST DOOR ACTUATOR . . . . . . . 49
PANEL/DEFROST DOOR . . . . . . . . . . . . . . . . . 45
RECIRCULATING AIR DOOR ACTUATOR . . . . 46
RECIRCULATING AIR DOOR . . . . . . . . . . . . . . 50
REFRIGERANT LINE COUPLER . . . . . . . . . . . 31
SOLAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . 41
TEMPERATURE/BLEND AIR DOOR MOTOR . . 44
TEMPERATURE/BLEND AIR DOOR . . . . . . . . . 50
VACUUM CHECK VALVE . . . . . . . . . . . . . . . . . 40
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . 40
ZG HEATING AND AIR CONDITIONING 24 - 1
GENERAL INFORMATION
HEATER AND AIR CONDITIONER
A manual temperature control type heati ng-ai r
condi ti oni ng system i s standard factory-i nstal l ed
equi pment on thi s model . An el ectroni cal l y control l ed
Automati c Temperature Control (ATC) type heati ng-
ai r condi ti oni ng system i s an avai l abl e factory-i n-
stal l ed opti on.
Al l vehi cl es are equi pped wi th a common heater-
A/C housi ng assembl y (Fi g. 1). The system combi nes
ai r condi ti oni ng, heati ng, and venti l ati ng capabi l i ti es
i n a si ngl e uni t housi ng mounted under the i nstru-
ment panel .
Outsi de fresh ai r enters the vehi cl e through the
cowl top openi ng at the base of the wi ndshi el d, and
passes through a pl enum chamber to the heater-A/C
system bl ower housi ng. Ai r fl ow vel oci ty can then be
adjusted wi th the bl ower motor speed sel ector swi tch
on the heater-A/C control panel . The ai r i ntake open-
i ngs must be kept free of snow, i ce, l eaves, and other
obstructi ons for the heater-A/C system to recei ve a
suffi ci ent vol ume of outsi de ai r.
Both the manual and ATC heater and ai r condi -
ti oner are bl end-ai r type systems. I n a bl end-ai r sys-
tem, a bl end-ai r door control s the amount of cool ed or
uncondi ti oned ai r i s al l owed to fl ow through, or
around, the heater core. A temperature control knob
on the heater-A/C control panel determi nes the di s-
charge ai r temperature by energi zi ng the bl end-ai r
door motor, whi ch operates the bl end-ai r door. Thi s
al l ows an al most i mmedi ate control of the output ai r
temperature of the system.
The mode control knob on the heater-A/C control
panel i s used to di rect the condi ti oned ai r to the
sel ected system outl ets. On manual temperature con-
trol systems, the mode control knob swi tches engi ne
vacuum to control the mode doors, whi ch are oper-
ated by vacuum actuator motors. On ATC systems,
the mode control knob swi tches el ectri cal current to
control the mode doors, whi ch are operated by el ec-
troni c actuator motors.
The outsi de ai r i ntake can be shut off by sel ecti ng
the reci rcul ati on mode wi th the mode control knob.
Thi s wi l l open the reci rcul ati ng ai r door and reci rcu-
l ate the ai r that i s al ready i nsi de the vehi cl e.
The ai r condi ti oner for al l model s i s desi gned for
the use of non-CFC, R-134a refri gerant. The ai r con-
di ti oni ng system has an evaporator to cool and dehu-
mi di fy the i ncomi ng fresh or reci rcul ated ai r pri or to
bl endi ng i t wi th the heated ai r. Thi s ai r condi ti oni ng
system uses a fi xed ori fi ce tube i n the condenser out-
l et l i ne to meter refri gerant fl ow to the evaporator
coi l . To mai ntai n mi ni mum evaporator temperature
and prevent evaporator freezi ng, a fi xed pressure set-
ti ng swi tch on the accumul ator cycl es the compressor
cl utch.
NOTE: This group covers both Left-Hand Drive
(LHD) and Right-Hand Drive (RHD) versions of this
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been
constructed as mirror-image of the LHD versions.
While most of the illustrations used in this group
represent only the LHD version, the diagnostic and
service procedures outlined can generally be
applied to either version. Exceptions to this rule
have been clearly identified as LHD or RHD, if a
special illustration or procedure is required.
HEATER AND AIR CONDITIONER CONTROLS
The manual temperature control heater-A/C sys-
tem uses a combi nati on of el ectri cal , and vacuum
control s. The ATC heater-A/C system uses onl y el ec-
tri cal control s. These control s provi de the vehi cl e
operator wi th a number of setti ng opti ons to hel p
control the cl i mate and comfort wi thi n the vehi cl e.
Refer to the owners manual for more i nformati on on
the suggested operati on and use of these control s.
Both heater-A/C control panel s are l ocated i nboard
of the i nstrument cl uster on the i nstrument panel
(Fi g. 2). Both control panel s have a temperature con-
trol knob, a mode control knob, a bl ower motor
swi tch knob, and an ai r condi ti oni ng compressor
pushbutton swi tch. The ATC control panel i ncl udes a
Reci rc pushbutton swi tch and a vacuum fl uorescent
di spl ay area.
The ATC control panel al so i ncl udes the ATC con-
trol l er. The ATC control l er contai ns a mi croprocessor
and uses i nternal programmi ng al ong wi th hard-
wi red sensor i nputs and messages recei ved on the
CCD data bus network to control the many functi ons
and features of the ATC system.
Fig. 1 Common Blend-Air Heater-Air
ConditionerSystem
TEMPERATURE BLEND/AIR DOOR EVAPORATOR CORE BLOWER PANEL DEFROST DOOR HEAT DEFROST DOOR HEATERCORE RECIRCULATING AIR DOOR
24 - 2 HEATING AND AIR CONDITIONING ZG
Both the manual heater-A/C control panel and the
ATC control panel and control l er uni ts cannot be
repai red. I f faul ty or damaged, the enti re uni t must
be repl aced.
SERVICE WARNINGS AND PRECAUTIONS
WARNING:
THE AIR CONDITIONING SYSTEM CONTAINS
REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER
SERVICE PROCEDURES. REPAIRS SHOULD ONLY
BE PERFORMED BY QUALIFIED SERVICE PERSON-
NEL.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO
OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELEC-
TRONIC LEAK DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF
REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIG-
ERANT AT AVERAGE TEMPERATURE AND ALTI-
TUDE IS EXTREMELY HIGH. AS A RESULT,
ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
THE SKIN OR DELICATE OBJECTS FROM DIRECT
CONTACT WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE
VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
CAUTION:
Liquid refrigerant is corrosive to metal sur-
faces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system
designed to use R-134a. Damage to the system will
result.
R-12 refrigerant oil must not be mixed with
R-134a refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the
R-134a system. Damage to the system will result.
Do not overcharge the refrigerant system. This
will cause excessive compressor head pressure
and can cause noise and system failure.
I n addi ti on to the warni ngs and cauti ons l i sted
above, the fol l owi ng precauti ons must al so be
observed whenever servi ci ng the ai r condi ti oni ng sys-
tem:
Recover the refri gerant before openi ng any fi t-
ti ng or connecti on. Open the fi tti ngs wi th cauti on,
even after the system has been di scharged. Never
open or l oosen a connecti on before recoveri ng the
refri gerant.
The refri gerant system must al ways be evacu-
ated before chargi ng.
Do not open the refri gerant system or uncap a
repl acement component unti l you are ready to servi ce
the system. Thi s wi l l prevent contami nati on i n the
system.
Before di sconnecti ng a component, cl ean the out-
si de of the fi tti ngs thoroughl y to prevent contami na-
ti on from enteri ng the refri gerant system.
I mmedi atel y after di sconnecti ng a component
from the refri gerant system, seal the open fi tti ngs
wi th a cap or pl ug.
Before connecti ng an open refri gerant fi tti ng,
al ways i nstal l a new seal or gasket. Coat the fi tti ng
and seal wi th cl ean refri gerant oi l before connecti ng.
Fig. 2 Heater-Air Conditioner Control Panels
MANUAL AIR CONDITIONING SYSTEM
AUTOMATIC TEMPERATURE CONTROL SYSTEM
ZG HEATING AND AIR CONDITIONING 24 - 3
GENERAL INFORMATION (Continued)
Do not remove the seal i ng caps from a repl ace-
ment component unti l i t i s to be i nstal l ed.
When i nstal l i ng a refri gerant l i ne, avoi d sharp
bends that may restri ct refri gerant fl ow. Posi ti on the
refri gerant l i nes away from exhaust system compo-
nents or any sharp edges, whi ch may damage the
l i ne.
Ti ghten refri gerant fi tti ngs onl y to the speci fi ed
torque. The al umi num fi tti ngs used i n the refri gerant
system wi l l not tol erate overti ghteni ng.
When di sconnecti ng a refri gerant fi tti ng, use a
wrench on both hal ves of the fi tti ng. Thi s wi l l pre-
vent twi sti ng of the refri gerant l i nes or tubes.
Refri gerant oi l wi l l absorb moi sture from the
atmosphere i f l eft uncapped. Do not open a contai ner
of refri gerant oi l unti l you are ready to use i t.
Repl ace the cap on the oi l contai ner i mmedi atel y
after usi ng. Store refri gerant oi l onl y i n a cl ean, ai r-
ti ght, and moi sture-free contai ner.
Keep servi ce tool s and the work area cl ean. Con-
tami nati on of the refri gerant system through carel ess
work habi ts must be avoi ded.
COOLING SYSTEM REQUIREMENTS
To mai ntai n the performance l evel of the heati ng-
ai r condi ti oni ng system, the engi ne cool i ng system
must be properl y mai ntai ned.
The use of a bug screen i s not recommended. Any
obstructi ons i n front of the radi ator or condenser wi l l
reduce the performance of the ai r condi ti oni ng and
engi ne cool i ng systems.
COOLANT PRECAUTIONS
WARNING:
ANTIFREEZE IS AN ETHYLENE GLYCOL
BASED COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO A FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY.
WASH THE SKIN AND CLOTHING THOR-
OUGHLY AFTER COMING IN CONTACT WITH ETH-
YLENE GLYCOL.
KEEP OUT OF THE REACH OF CHILDREN
AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE.
PERSONAL INJURY MAY RESULT.
DO NOT STORE ENGINE COOLANT IN OPEN
OR UNMARKED CONTAINERS.
HOT ENGINE COOLANT CAN CAUSE SEVERE
BURNS. DO NOT OPEN THE RADIATOR DRAIN
COCK WHEN THE COOLING SYSTEM IS HOT AND
PRESSURIZED. ALLOW THE COOLANT TO REACH
TO ROOM TEMPERATURE BEFORE STARTING
REPAIR OPERATIONS.
The engi ne cool i ng system i s desi gned to devel op
i nternal pressures of 97 to 124 kPa (14 to 18 psi ).
Al l ow the vehi cl e 15 mi nutes to cool down, or wai t
unti l a safe temperature and pressure are attai ned,
before openi ng the cool i ng system. Refer to Group 7 -
Cool i ng System for more i nformati on.
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS
Ki nks or sharp bends i n the refri gerant pl umbi ng
wi l l reduce the capaci ty of the enti re system. Hi gh
pressures are produced i n the system when i t i s oper-
ati ng. Extreme care must be exerci sed to make sure
that al l refri gerant system connecti ons are pressure
ti ght.
A good rul e for the fl exi bl e hose refri gerant l i nes i s
to keep the radi us of al l bends at l east ten ti mes the
di ameter of the hose. Sharp bends wi l l reduce the
fl ow of refri gerant. The fl exi bl e hose l i nes shoul d be
routed so they are at l east 80 mm (3 i nches) from the
exhaust mani fol d. I t i s a good practi ce to i nspect al l
fl exi bl e refri gerant system hose l i nes at l east once a
year to make sure they are i n good condi ti on and
properl y routed.
There are two types of refri gerant fi tti ngs:
Al l fi tti ngs wi th O-ri ngs need to be coated wi th
refri gerant oi l before i nstal l ati on. Use onl y O-ri ngs
approved for use wi th R-134a refri gerant. Fai l ure to
do so may resul t i n a l eak.
Uni fi ed pl umbi ng connecti ons wi th al umi num
gaskets cannot be servi ced wi th O-ri ngs. The gaskets
are not reusabl e and new gaskets do not requi re
l ubri cati on before i nstal l i ng.
Usi ng the proper tool s when maki ng a refri gerant
pl umbi ng connecti on i s very i mportant. I mproper
tool s or i mproper use of the tool s can damage the
refri gerant fi tti ngs. Al ways use two wrenches when
l ooseni ng or ti ghteni ng tube fi tti ngs. Use one wrench
to hol d one si de of the connecti on stati onary, whi l e
l ooseni ng or ti ghteni ng the other si de of the connec-
ti on wi th a second wrench.
The refri gerant must be recovered compl etel y from
the system before openi ng any fi tti ng or connecti on.
Open the fi tti ngs wi th cauti on, even after the refri g-
erant has been recovered. I f any pressure i s noti ced
as a fi tti ng i s l oosened, ti ghten the fi tti ng and
recover the refri gerant from the system agai n.
Do not di scharge refri gerant i nto the atmosphere.
Use an R-134a refri gerant recovery/recycl i ng devi ce
that meets SAE Standard J2210.
The refri gerant system wi l l remai n chemi cal l y sta-
bl e as l ong as pure, moi sture-free R-134a refri gerant
and refri gerant oi l i s used. Di rt, moi sture, or ai r can
upset thi s chemi cal stabi l i ty. Operati onal troubl es or
seri ous damage can occur i f forei gn materi al i s
present i n the refri gerant system.
24 - 4 HEATING AND AIR CONDITIONING ZG
GENERAL INFORMATION (Continued)
When i t i s necessary to open the refri gerant sys-
tem, have everythi ng needed to servi ce the system
ready. The refri gerant system shoul d not be l eft open
to the atmosphere any l onger than necessary. Cap or
pl ug al l l i nes and fi tti ngs as soon as they are opened
to prevent the entrance of di rt and moi sture. Al l l i nes
and components i n parts stock shoul d be capped or
seal ed unti l they are to be i nstal l ed.
Al l tool s, i ncl udi ng the refri gerant recycl i ng equi p-
ment, the mani fol d gauge set, and test hoses shoul d
be kept cl ean and dry. Al l tool s and equi pment must
be desi gned for R-134a refri gerant.
DESCRIPTION AND OPERATION
ACCUMULATOR
The accumul ator i s mounted i n the engi ne com-
partment between the evaporator coi l outl et tube and
the compressor i nl et. Refri gerant enters the accumu-
l ator cani ster as a l ow pressure vapor through the
i nl et tube.
Any l i qui d, oi l -l aden refri gerant fal l s to the bottom
of the cani ster, whi ch acts as a separator. A desi ccant
bag i s mounted i nsi de the accumul ator cani ster to
absorb any moi sture whi ch may have entered and
become trapped i n the refri gerant system (Fi g. 3).
AMBIENT TEMPERATURE SENSOR
Model s wi th the opti onal Automati c Temperature
Control (ATC) system use an i nput from the ambi ent
temperature sensor. The sensor i s l ocated i n front of
the condenser and behi nd the gri l l e on the center
radi ator support.
The ambi ent temperature sensor i s hard-wi red to
the Body Control Modul e (BCM). The BCM pl aces an
ambi ent temperature message on the CCD data bus
for use by the overhead consol e for the thermometer
functi on, and for use by the ATC control l er.
The ambi ent temperature sensor i s a Negati ve
Temperature Coeffi ci ent (NTC) thermi stor or temper-
ature sensi ti ve resi stor. The ATC control l er uses thi s
sensor i nput to moni tor the outsi de ai r temperature.
However, because heat from the radi ator and con-
denser can affect the accuracy of thi s sensor i nput
when the vehi cl e i s not movi ng, thi s i nput i s onl y
used by the ATC system when the vehi cl e i s i n
moti on.
The ambi ent temperature sensor cannot be
adjusted or repai red and, i f faul ty or damaged, i t
must be repl aced.
BLOWER MOTOR
The bl ower motor and bl ower wheel are l ocated i n
the passenger si de end of the heater-A/C housi ng,
bel ow the gl ove box modul e. The bl ower motor con-
trol s the vel oci ty of the ai r fl owi ng through the heat-
er-A/C housi ng by spi nni ng a squi rrel cage-type
bl ower wheel wi thi n the bl ower housi ng at the
sel ected speed. The bl ower motor and bl ower wheel
can be servi ced from the passenger compartment si de
of the housi ng. The bl ower motor ci rcui t i s protected
by a fuse i n the juncti on bl ock.
The bl ower motor wi l l onl y operate when the i gni -
ti on swi tch i s i n the On posi ti on, and the heater-A/C
mode control swi tch i s i n any posi ti on except Off. On
model s wi th the standard manual temperature con-
trol system, the bl ower motor speed i s control l ed by
the bl ower motor swi tch and resi stor. On model s wi th
the opti onal Automati c Temperature Control (ATC)
system, the bl ower motor speed i s control l ed by the
bl ower motor swi tch and the power modul e.
The bl ower motor and bl ower wheel cannot be
repai red and, i f faul ty or damaged, they must be
repl aced. The bl ower motor and bl ower wheel are
each servi ced separatel y.
BLOWER MOTOR POWER MODULE
Model s equi pped wi th the opti onal Automati c Tem-
perature Control (ATC) system have a bl ower motor
power modul e. The power modul e al l ows i nfi ni tel y
vari abl e bl ower motor speeds. The power modul e i s
mounted to the heater-A/C housi ng, under the i nstru-
ment panel and just i nboard of the bl ower motor, i n
Fig. 3 Accumulator - Typical
INLET FROM EVAPORATOR CLUTCH CYCLING PRES- SURE SWITCH PRESSURE SWITCH FITTING OUTLET TO COM- PRESSOR ANTI-SIPHON HOLE DESICCANT BAG OIL RETURN ORIFICE FIL- TER VAPOR RETURN TUBE ACCUMULATOR DOME O-RING SEAL
ZG HEATING AND AIR CONDITIONING 24 - 5
GENERAL INFORMATION (Continued)
the same l ocati on used for the bl ower motor resi stor
on manual temperature control systems. I t can be
accessed wi thout removi ng any other components.
The power modul e output to the bl ower motor can
be control l ed manual l y by usi ng the bl ower motor
swi tch knob on the ATC heater-A/C control panel , or
automati cal l y by the ci rcui try of the ATC control l er.
I n ei ther case, the ATC control l er sends the correct
pul se wi dth modul ated si gnal to the power modul e to
obtai n the sel ected or programmed bl ower motor
speed.
The power modul e cannot be repai red and, i f faul ty
or damaged, i t must be repl aced.
BLOWER MOTOR RESISTOR
Model s wi th the standard manual temperature
control system have a bl ower motor resi stor. The
bl ower motor resi stor i s mounted to the heater-A/C
housi ng, under the i nstrument panel and just
i nboard of the bl ower motor. I t can be accessed wi th-
out removi ng any other components.
The resi stor has mul ti pl e resi stor wi res, each of
whi ch wi l l change the resi stance i n the bl ower motor
ground path to change the bl ower motor speed. The
bl ower motor swi tch di rects the ground path through
the correct resi stor wi re to obtai n the sel ected bl ower
motor speed.
Wi th the bl ower motor swi tch i n the l owest speed
posi ti on, the ground path for the motor i s appl i ed
through al l of the resi stor wi res. Each hi gher speed
sel ected wi th the bl ower motor swi tch appl i es the
bl ower motor ground path through fewer of the resi s-
tor wi res, i ncreasi ng the bl ower motor speed. When
the bl ower motor swi tch i s i n the hi ghest speed posi -
ti on, the bl ower motor resi stor i s bypassed and the
bl ower motor recei ves a di rect path to ground.
The bl ower motor resi stor cannot be repai red and,
i f faul ty or damaged, i t must be repl aced.
BLOWER MOTOR SWITCH
The heater-A/C bl ower motor i s control l ed by a
rotary swi tch mounted i n the heater-A/C control
panel . On vehi cl es wi th manual temperature control
systems, the swi tch al l ows the sel ecti on of four
bl ower motor speeds, but wi l l onl y operate wi th the
i gni ti on swi tch i n the On posi ti on, and the heater-
A/C mode control swi tch i n any posi ti on except Off.
On vehi cl es wi th Automati c Temperature Control
(ATC) systems, the swi tch al l ows the sel ecti on of Lo
Auto, Hi Auto, and an i nfi ni te number of manual
speed setti ngs between Lo and Hi .
On manual temperature control systems, the
bl ower motor swi tch i s connected i n seri es wi th the
bl ower motor ground path through the heater-A/C
mode control swi tch. The bl ower motor swi tch di rects
thi s ground path to the bl ower motor through the
bl ower motor resi stor wi res, or di rectl y to the bl ower
motor, as requi red to achi eve the sel ected bl ower
motor speed.
On ATC systems, the bl ower motor swi tch i s just
one of many i nputs to the ATC control l er. I n the
manual bl ower modes, the ATC control l er adjusts the
bl ower motor speed through the power modul e or the
hi gh speed bl ower motor rel ay as requi red by the
sel ected bl ower swi tch posi ti on. I n the auto bl ower
modes, the ATC control l er i s programmed to sel ect
and adjust the bl ower motor speed through the
power modul e or the hi gh speed bl ower motor rel ay
as requi red to achi eve and mai ntai n the sel ected
comfort l evel .
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, i t must be repl aced. The swi tch i s
servi ced onl y as a part of the heater-A/C control
assembl y.
COMPRESSOR
The ai r condi ti oni ng system uses a Ni ppon Denso
10PA17 fi xed di spl acement compressor on al l model s.
A l abel i denti fyi ng the use of R-134a refri gerant i s
l ocated on the compressor. The purpose of the com-
pressor i s to compress the l ow-pressure refri gerant
vapor from the evaporator i nto a hi gh-pressure, hi gh-
temperature vapor.
The compressor cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
COMPRESSOR CLUTCH
The compressor cl utch i s control l ed by several com-
ponents: the A/C compressor swi tch on the heater-
A/C control panel , the ATC control l er, the l ow
pressure cycl i ng cl utch swi tch, the hi gh pressure cut-
off swi tch, the compressor cl utch rel ay, and the Pow-
ertrai n Control Modul e (PCM). The PCM may del ay
compressor cl utch engagement for up to thi rty sec-
onds. Refer to Group 14 - Fuel System for more i nfor-
mati on on the PCM control s.
GASOLINE ENGINE
The compressor cl utch assembl y consi sts of a sta-
ti onary el ectromagneti c coi l , a hub beari ng and pul -
l ey assembl y, and a cl utch pl ate (Fi g. 4). The
el ectromagneti c coi l and pul l ey are retai ned on the
compressor wi th snap ri ngs. The cl utch pl ate i s
mounted on the compressor shaft and secured wi th a
bol t.
These components provi de the means to engage
and di sengage the compressor from the engi ne ser-
penti ne accessory dri ve bel t. When the cl utch coi l i s
energi zed, i t magneti cal l y draws the cl utch i nto con-
tact wi th the pul l ey and dri ves the compressor shaft.
When the coi l i s not energi zed, the pul l ey freewheel s
on the cl utch hub beari ng, whi ch i s part of the pul l ey.
24 - 6 HEATING AND AIR CONDITIONING ZG
DESCRIPTION AND OPERATION (Continued)
The compressor cl utch and coi l are the onl y servi ced
parts on the compressor.
DIESEL ENGINE
The compressor cl utch assembl y consi sts of a sta-
ti onery el ectromagneti c coi l , a hub beari ng and rotor
assembl y, and a cl utch pl ate (Fi g. 5). The el ectromag-
neti c coi l and rotor are retai ned on the compressor
wi th snap ri ngs. The cl utch pl ate i s mounted on the
compressor shaft and secured wi th a bol t.
The compressor i s mounted on the l eft si de of the
engi ne bl ock behi nd the power steeri ng pump. The
compressor i s dri ven by a spl i ned shaft off the rear of
the power steeri ng pump. The spl i ned shaft has a
dri ve fl ange mounted to i t whi ch attaches to a dri ve
spool . The spool l i nks the compressor cl utch pl ate to
the steeri ng pump dri ve fl ange. When the cl utch coi l
i s energi zed, i t magneti cal l y draws the cl utch pl ate
i nto contact wi th the rotor and dri ves the compressor
shaft. When the coi l i s not energi zed, the rotor free-
wheel s on the cl utch hub beari ng, whi ch i s part of
the rotor. The compressor cl utch and coi l are the onl y
servi ced parts on the compressor.
COMPRESSOR CLUTCH RELAY
The compressor cl utch rel ay i s a I nternati onal
Standards Organi zati on (I SO) mi cro-rel ay. The termi -
nal desi gnati ons and functi ons are the same as a con-
venti onal I SO rel ay. However, the mi cro-rel ay
termi nal ori entati on (footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the rel ay case di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
The compressor cl utch rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the compres-
sor cl utch coi l when the Powertrai n Control Modul e
(PCM) grounds the coi l si de of the rel ay. The PCM
responds to i nputs from the A/C compressor swi tch
on the heater-A/C control panel , the ATC control l er,
the l ow pressure cycl i ng cl utch swi tch, and the hi gh
pressure cut-off swi tch. See the Di agnosi s and Test-
i ng secti on of thi s group for more i nformati on on the
operati on of the compressor cl utch rel ay.
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment. Refer to the PDC l abel for rel ay i denti fi cati on
and l ocati on.
The compressor cl utch rel ay cannot be repai red
and, i f faul ty or damaged, i t must be repl aced.
CONDENSER
The condenser i s l ocated i n front of the engi ne cool -
i ng radi ator. I t i s a heat exchanger that al l ows the
hi gh-pressure refri gerant gas to gi ve up i ts heat to
the ai r passi ng over the condenser fi ns. Thi s causes
the refri gerant gas to condense i nto a hi gh-pressure
l i qui d refri gerant.
The condenser cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
EVAPORATOR COIL
The evaporator coi l i s l ocated i n the heater-A/C
housi ng, under the i nstrument panel . Refri gerant
enters the evaporator as a l ow-temperature, l ow-
pressure l i qui d. As ai r passes over the fi ns of the
evaporator, the humi di ty i n the ai r condenses on the
fi ns, and the heat from the ai r i s absorbed by the
refri gerant. Heat absorpti on causes the refri gerant to
become a l ow-pressure gas before i t l eaves the evap-
orator.
The evaporator coi l cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
FIXED ORIFICE TUBE
The fi xed ori fi ce tube i s i ntegral to the l i qui d l i ne
l ocated between the outl et tube of the condenser and
the i nl et tube of the evaporator. The i nl et and outl et
ends of the tube have a screen to fi l ter the refri ger-
Fig. 4 Compressor Clutch - Gasoline Engine
CLUTCH PLATE SHAFT KEY PULLEY COIL CLUTCH SHIMS SNAP RING SNAP RING
Fig. 5 Compressor Clutch - Diesel Engine
COIL CLUTCH ROTOR CLUTCH PLATE SNAP RING SNAP RING
ZG HEATING AND AIR CONDITIONING 24 - 7
DESCRIPTION AND OPERATION (Continued)
ant. O-ri ngs on the tube body prevent the refri gerant
from bypassi ng the fi xed ori fi ce. The fi xed ori fi ce
tube i s used to meter the fl ow of l i qui d refri gerant
i nto the evaporator coi l .
The fi xed ori fi ce tube cannot be repai red and, i f
faul ty or pl ugged, the l i qui d l i ne uni t must be
repl aced.
HEATER CORE
The heater core i s l ocated i n the heater-A/C hous-
i ng, under the i nstrument panel . I t i s a heat
exchanger made of rows of tubes and fi ns. Engi ne
cool ant i s ci rcul ated through heater hoses to the
heater core at al l ti mes. As the cool ant fl ows through
the heater core, heat removed from the engi ne i s
transferred to the heater core fi ns and tubes.
Ai r di rected through the heater core pi cks up the
heat from the heater core fi ns. The bl end ai r door
al l ows control of the heater output ai r temperature
by control l i ng how much of the ai r fl owi ng through
the heater-A/C housi ng i s di rected through the
heater core. The bl ower motor speed control s the
amount of ai r fl owi ng through the heater-A/C hous-
i ng.
The heater core cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
HIGH PRESSURE CUT-OFF SWITCH
The hi gh pressure cut-off swi tch i s l ocated on the
di scharge l i ne near the compressor. Thi s swi tch i s
connected i n seri es between the l ow pressure cl utch
cycl i ng swi tch and the Powertrai n Control Modul e
(PCM). Thi s swi tch prevents compressor operati on
when the di scharge l i ne pressure approaches hi gh
l evel s.
When the di scharge l i ne pressure ri ses above 3100
to 3375 kPa (450 to 490 psi ) the swi tch contacts open
and i nterrupt the A/C request si gnal ci rcui t to the
PCM. The PCM responds by de-energi zi ng the com-
pressor cl utch rel ay, whi ch wi l l cause the compressor
cl utch to di sengage. The swi tch wi l l cl ose agai n when
the pressure drops to 1860 to 2275 kPa (270 to 330
psi ).
The hi gh pressure cut-off swi tch i s a factory-cal i -
brated uni t. The swi tch cannot be adjusted or
repai red and, i f faul ty or damaged, i t must be
repl aced.
HIGH PRESSURE RELIEF VALVE
The hi gh pressure rel i ef val ve i s l ocated on the
compressor mani fol d. The val ve i s used to prevent
excessi ve system pressure. The val ve vents the sys-
tem when a pressure of 3445 to 4135 kPa (500 to 600
psi ) and above, i s reached. Thi s prevents damage to
the compressor and other system components due to
condenser ai r fl ow bei ng restri cted or an overcharge
of refri gerant. The val ve cl oses wi th a mi ni mum
pressure of 2756 kPa (400 psi ).
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce system pressure, then re-seats
i tsel f. The majori ty of the refri gerant i s conserved i n
the system. I f the val ve vents refri gerant, i t does not
mean the val ve i s faul ty. The val ve i s onl y servi ced
as part of the compressor assembl y, and must not be
removed or otherwi se di sturbed.
HIGH SPEED BLOWER MOTOR RELAY
Model s equi pped wi th the opti onal Automati c Tem-
perature Control (ATC) system have a hi gh speed
bl ower motor rel ay. The rel ay i s a I nternati onal Stan-
dards Organi zati on (I SO)-type rel ay.
The hi gh speed bl ower motor rel ay i s a el ectrome-
chani cal devi ce that swi tches battery current to the
bl ower motor, bypassi ng the bl ower motor power
modul e, when the rel ay coi l i s provi ded a ground si g-
nal by the ATC control l er. See the Di agnosi s and
Testi ng secti on of thi s group for more i nformati on on
the operati on of the hi gh speed bl ower motor rel ay.
The hi gh speed bl ower motor rel ay i s l ocated on
the passenger si de outboard end of the heater-A/C
housi ng, near the bl ower motor i n the passenger
compartment.
The hi gh speed bl ower motor rel ay cannot be
repai red and, i f faul ty or damaged, i t must be
repl aced.
IN-VEHICLE TEMPERATURE SENSOR
Model s equi pped wi th the opti onal Automati c Tem-
perature Control (ATC) system have an i n-vehi cl e
temperature sensor. The i n-vehi cl e temperature sen-
sor i s l ocated behi nd the gl ove box modul e, just
i nboard of the gl ove box and bel ow the passenger
si de center panel outl et.
The i n-vehi cl e temperature sensor i s a Negati ve
Temperature Coeffi ci ent (NTC) thermi stor or temper-
ature sensi ti ve resi stor. Ai r passi ng over a venturi i n
the heater-A/C housi ng creates a vacuum, whi ch
draws ai r from i nsi de the vehi cl e past the sensor
through an aspi rator hose and tube. The sensor pro-
vi des a si gnal to the ATC control l er wi th a val ue that
represents the temperature of the ai r i nsi de the vehi -
cl e.
The ATC control l er uses the i n-vehi cl e temperature
sensor si gnal i nput to adjust the bl ower speed, bl end-
ai r door posi ti on, and mode door sel ecti on i n order to
mai ntai n the sel ected comfort l evel . The sensor can-
not be adjusted or repai red and, i f faul ty or damaged,
i t must be repl aced.
LOW PRESSURE CYCLING CLUTCH SWITCH
The l ow pressure cycl i ng cl utch swi tch i s mounted
on top of the accumul ator. The swi tch i s connected i n
24 - 8 HEATING AND AIR CONDITIONING ZG
DESCRIPTION AND OPERATION (Continued)
seri es wi th the hi gh pressure cut-off swi tch, between
ground and the Powertrai n Control Modul e (PCM).
The swi tch contacts open and cl ose causi ng the
PCM to turn the compressor cl utch on and off. Thi s
regul ates the system pressure and control s evapora-
tor temperature. Control l i ng evaporator temperature
prevents condensate water on the evaporator fi ns
from freezi ng and obstructi ng ai r condi ti oni ng system
ai r fl ow.
The swi tch contacts are normal l y open when the
sucti on pressure i s approxi matel y 172 kPa (25 psi ) or
l ower. The swi tch contacts wi l l cl ose when the suc-
ti on pressure ri ses to approxi matel y 296 kPa (43 psi )
or above.
Lower ambi ent temperatures, bel ow approxi matel y
-1 C (30 F) duri ng col d weather wi l l al so open the
swi tch contacts. Thi s i s due to the pressure/tempera-
ture rel ati onshi p of the refri gerant i n the system.
The l ow pressure cycl i ng cl utch swi tch i s a factory-
cal i brated uni t. Thi s swi tch cannot be adjusted or
repai red. I f faul ty or damaged, the swi tch must be
repl aced.
REFRIGERANT
The R-134a refri gerant used i n thi s ai r condi ti on-
i ng system i s a non-toxi c, non-fl ammabl e, cl ear, and
col orl ess l i quefi ed gas. R-134a refri gerant i s not com-
pati bl e wi th R-12 refri gerant i n an ai r condi ti oni ng
system.
Even a smal l amount of R-12 added to a R-134a
refri gerant system, wi l l cause compressor fai l ure,
refri gerant oi l sl udge, or poor ai r condi ti oni ng system
performance. The refri gerant system servi ce ports
have been desi gned to ensure that the system i s not
acci dental l y fi l l ed wi th the wrong refri gerant (R-12).
REFRIGERANT LINE COUPLER
Spri ng-l ocki ng refri gerant l i ne coupl ers are used to
connect refri gerant l i nes and other components to the
refri gerant system. The coupl i ng i s hel d together by
a garter spri ng i nsi de a ci rcul ar cage.
When the coupl i ng hal ves are connected, the fl ared
end of the femal e fi tti ng sl i ps behi nd the garter
spri ng i nsi de the cage of the mal e fi tti ng. The garter
spri ng and cage prevent the fl ared end of the femal e
fi tti ng from pul l i ng out of the cage. Secondary cl i ps
are i nstal l ed over the coupl i ng at the factory for
added bl owoff protecti on.
O-ri ngs are used to seal the coupl i ng. These
O-ri ngs are compati bl e wi th R-134a refri gerant and
must be repl aced wi th O-ri ngs made of the same
materi al .
REFRIGERANT LINE
The refri gerant l i nes are used to carry the refri g-
erant between the vari ous ai r condi ti oni ng system
components. A barri er hose desi gn i s used for the ai r
condi ti oni ng system on thi s vehi cl e.
The ends of the refri gerant hoses are made from
l i ghtwei ght al umi num, and use braze-l ess fi tti ngs.
The refri gerant l i nes and hoses cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
REFRIGERANT OIL
The oi l used i n the 10PA17 compressor i s a pol y-
al kyl ene gl ycol , syntheti c (ND8 PAG), wax-free refri g-
erant oi l . Use onl y refri gerant oi l of the same type to
servi ce the system.
Refri gerant oi l wi l l absorb any moi sture i t comes i n
contact wi th, even moi sture i n the ai r. The oi l con-
tai ner shoul d be kept ti ghtl y capped unti l i t i s ready
to be used. Then, cap the oi l i mmedi atel y after usi ng,
to prevent contami nati on.
REFRIGERANT SYSTEM SERVICE EQUIPMENT
When servi ci ng the ai r condi ti oni ng system, a
refri gerant chargi ng stati on and a recovery/recycl i ng
devi ce for R-134a must be used. Thi s devi ce must
meet SAE Standard J2210. Contact an automoti ve
servi ce equi pment suppl i er for refri gerant chargi ng
and recycl i ng/recoveri ng equi pment. Refer to the
operati ng i nstructi ons provi ded wi th the equi pment
for proper operati on.
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED,
BEFORE CONNECTING TO OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
A mani fol d gauge set may be needed wi th some
chargi ng and/or recovery/recycl i ng devi ces (Fi g. 6).
The servi ce hoses on the gauge set bei ng used shoul d
have manual (turn wheel ), or automati c back-fl ow
val ves at the servi ce port connector ends. Thi s wi l l
prevent refri gerant from bei ng rel eased i nto the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE
The l ow pressure hose (Bl ue wi th Bl ack stri pe)
attaches to the sucti on servi ce port. Thi s port i s
l ocated on the sucti on l i ne, near the front of the
engi ne compartment.
ZG HEATING AND AIR CONDITIONING 24 - 9
DESCRIPTION AND OPERATION (Continued)
HIGH PRESSURE GAUGE HOSE
The hi gh pressure hose (Red wi th Bl ack stri pe)
attaches to the di scharge servi ce port. Thi s port i s
l ocated on the di scharge l i ne between the compressor
and the condenser, near the front of the engi ne com-
partment.
RECOVERY/RECYCLING/EVACUATION/CHARGING
HOSE
The center mani fol d hose (Yel l ow or Whi te, wi th
Bl ack stri pe) i s used to recover, evacuate, and charge
the refri gerant system. When the l ow or hi gh pres-
sure val ves on the mani fol d gauge set are opened,
the refri gerant i n the system wi l l escape through thi s
hose.
REFRIGERANT SYSTEM SERVICE PORTS
The refri gerant system servi ce ports are used to
charge, recover/recycl e, evacuate, and test the ai r
condi ti oni ng refri gerant system. Uni que servi ce port
fi tti ng si zes are used on the R-134a system, to ensure
that the refri gerant system i s not acci dental l y con-
tami nated by the use of the wrong refri gerant (R-12),
or refri gerant system servi ce equi pment.
The hi gh pressure servi ce port i s l ocated on the
compressor mani fol d or pl umbi ng, near the front of
the engi ne compartment. The l ow pressure servi ce
port i s l ocated on the sucti on l i ne, near the front of
the engi ne compartment.
After servi ci ng the refri gerant system, al ways rei n-
stal l the servi ce port caps.
SOLAR SENSOR
Model s equi pped wi th the opti onal Automati c Tem-
perature Control (ATC) system have a sol ar sensor.
The sol ar sensor i s mounted i n the cowl top tri m
panel , on the top of the i nstrument panel near the
passenger si de defroster outl et. The sensor i s a photo
di ode whi ch responds to sunl i ght i ntensi ty, not to
temperature.
The ATC control l er uses the sol ar sensor i nput to
cal cul ate and compensate for the potenti al effects of
heat gai n i n bri ght sunl i ght, and heat l oss wi th an
overcast sky or at ni ght. I t then adjusts the bl ower
motor speed, bl end ai r door posi ti on, and mode door
posi ti on as needed to mai ntai n the sel ected comfort
l evel .
The sol ar sensor cannot be adjusted or repai red
and, i f faul ty or damaged, i t must be repl aced.
VACUUM CHECK VALVE
A one-way vacuum check val ve i s i nstal l ed i n the
accessory vacuum suppl y l i ne near the vacuum tap
on the engi ne i ntake mani fol d. Thi s check val ve
hel ps to mai ntai n the system vacuum needed to
retai n the sel ected heater-A/C mode setti ngs. I t pre-
vents the engi ne from bl eedi ng down system vacuum
through the i ntake mani fol d duri ng extended heavy
engi ne l oad (l ow engi ne vacuum) operati on.
The vacuum check val ve cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
VACUUM RESERVOIR
The vacuum reservoi r i s mounted i n the engi ne
compartment on the undersi de of the battery tray.
Vacuum stored i n the reservoi r i s used to operate the
vacuum-control l ed vehi cl e accessori es duri ng peri ods
of l ow engi ne vacuum, such as when the vehi cl e i s
cl i mbi ng a steep grade or under other hi gh engi ne
l oad operati ng condi ti ons.
The vacuum reservoi r cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
DIAGNOSIS AND TESTING
A/C PERFORMANCE
The ai r condi ti oni ng system i s desi gned to provi de
the passenger compartment wi th l ow temperature
and l ow humi di ty ai r. The evaporator, l ocated i n the
heater-A/C housi ng behi nd the i nstrument panel , i s
cool ed to temperatures near the freezi ng poi nt. As
warm damp ai r passes over the fi ns i n the evapora-
tor, the ai r i s cool ed and the moi sture i s removed as
i t condenses on the fi ns. Duri ng peri ods of hi gh heat
and humi di ty, an ai r condi ti oni ng system wi l l be
more effecti ve i n the Reci rcul ati on mode. Wi th the
system i n the Reci rcul ati on mode, onl y ai r from the
passenger compartment passes through the evapora-
Fig. 6 Manifold Gauge Set - Typical
LOW PRESSURE GAUGE HIGH PRESSURE GAUGE VALVE VACUUM/REFRIG- ERANT HOSE (YEL- LOW W/BLACK STRIP) HIGH PRESSURE HOSE (RED W/BLACK STRIP) LOW PRESSURE HOSE (BLUE W/BLACK STRIP) VALVE
24 - 10 HEATING AND AIR CONDITIONING ZG
DESCRIPTION AND OPERATION (Continued)
tor. As the passenger compartment ai r dehumi di fi es,
the ai r condi ti oni ng system performance l evel s
i mprove.
Humi di ty has an i mportant beari ng on the tempera-
ture of the ai r del i vered to the i nteri or of the vehi cl e. I t
i s i mportant to understand the effect that humi di ty has
on the performance of the ai r condi ti oni ng system.
When humi di ty i s hi gh, the evaporator has to perform a
doubl e duty. I t must l ower the ai r temperature, and i t
must l ower the temperature of the moi sture i n the ai r
that condenses on the evaporator fi ns. Condensi ng the
moi sture i n the ai r transfers heat energy i nto the evap-
orator fi ns and tubi ng. Thi s reduces the amount of heat
the evaporator can absorb from the ai r. Hi gh humi di ty
greatl y reduces the abi l i ty of the evaporator to l ower
the temperature of the ai r.
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Wri ng-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from thei r
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
I f the vehi cl e has the opti onal Automati c Tempera-
ture Control (ATC) system, and has i ntermi ttent
operati onal probl ems or faul t codes, be certai n that
the 16-way wi re harness connector on the heater-A/C
housi ng i s properl y seated (Fi g. 7). To check thi s con-
di ti on, unpl ug the two wi re harness connector hal ves,
then pl ug them i n agai n. Hi stori cal faul t codes that
coul d be stored as a resul t of thi s unseated wi re har-
ness connector condi ti on are Codes 36, 38, and 39.
Revi ew the Servi ce Warni ngs and Precauti ons i n
the front of thi s group before performi ng thi s proce-
dure. The ai r temperature i n the test room and i n
the vehi cl e must be a mi ni mum of 21 C (70 F) for
thi s test.
(1) Connect a tachometer and a mani fol d gauge
set.
(2) Set the heater-A/C control s i n the A/C, Panel ,
and Reci rcul ati on posi ti ons, the temperature control
knob i n the ful l cool posi ti on, and the bl ower motor
swi tch i n the ful l Hi gh posi ti on.
(3) Start the engi ne and hol d the i dl e at 1,000 rpm
wi th the compressor cl utch engaged.
(4) The engi ne shoul d be at operati ng temperature.
The doors and wi ndows must be open.
(5) I nsert a thermometer i n the dri ver si de center
A/C (panel ) outl et. Operate the engi ne for fi ve mi n-
utes.
(6) The compressor cl utch may cycl e, dependi ng
upon the ambi ent temperature and humi di ty. I f the
cl utch cycl es, unpl ug the l ow pressure cycl i ng cl utch
swi tch wi re harness connector from the swi tch
l ocated on the accumul ator (Fi g. 8). Pl ace a jumper
Ambient 21C 27C 32C 38C 43C
Temperature (70F) (80F) (90F) (100F) (110F)
Air Temperature -3 to 3C 1 to 7C 3 to 9C 6 to 13C 10 to 18C
at Center Panel
Outlet (27-38F) (33-44F) (37-48F) (43-55F) (50-64F)
Evaporator 179-241 kPa 221-283 kPa 262-324 kPa 303-365 kPa 345-414 kPa
Inlet Pressure
at Charge Port (26-35 psi) (32-41 psi) (38-47 psi) (44-53 psi) (50-60 psi)
Compressor 1240-1655 kPa 1380-1790 kPa 1720-2070 kPa 1860-2345 kPa 2070-2690 kPa
Discharge
Pressure (180-240 psi) (200-260 psi) (250-300 psi) (270-340 psi) (300-390 psi)
Performance Temperature and Pressure
Fig. 7 16-Way Wire Harness Connector
RECIRCULATING DOOR SHAFT RETAINER ROD CLIP ACTUATOR 16 WAY CONNECTOR BLOWER MOTOR ELEC- TRICAL CON- NECTOR BLOWER MOTOR ELECTRICAL CON- NECTOR
ZG HEATING AND AIR CONDITIONING 24 - 11
DIAGNOSIS AND TESTING (Continued)
wi re between the two cavi ti es of the l ow pressure
cycl i ng cl utch swi tch wi re harness connector.
(7) Wi th the compressor cl utch engaged, record the
di scharge ai r temperature and the compressor di s-
charge pressure.
(8) Compare the di scharge ai r temperature to the
Performance Temperature and Pressure chart. I f the
di scharge ai r temperature i s hi gh, see Refri gerant Sys-
tem Leaks and Refri gerant System Charge i n thi s
group.
(9) Compare the compressor di scharge pressure to
the Performance Temperature and Pressure chart. I f
the compressor di scharge pressure i s hi gh, see the
Pressure Di agnosi s chart.
Fig. 8 Low Pressure Cycling Clutch Switch
CLUTCH CYCLING PRES- SURE SWITCH ACCUMULATOR
24 - 12 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
Pressure Diagnosis
TEMPERATURE IN TEST AREA 2138C (170100F) VERIFY R134a CHARGE CONNECT MANIFOLD GAUGES. SEE REFRIGERANT SECTION IN THIS GROUP. IF R134a CHARGE IS LOW, CORRECT LEAK, EVACUATE, AND CHARGE SYSTEM START ENGINE ADJUST IDLE TO 1000 RPM IN PARK OR NEUTRAL WITH PARK BRAKE SET CLUTCH DOES NOT ENGAGE NO PRESSURE OR ELEC- TRICAL POWER TO CYCLING CLUTCH SWITCH OPEN PASSENGER COMPARTMENT, WINDOWS AND/OR DOORS SET CONTROL TO A/C PANEL, HIGH BLOWER, RECIRC MODE NORMAL CLUTCH CYCLE RAPID CLUTCH CYCLE 10 OR MORE CYCLES PER MINUTE LOW REFRIGERANT CHARGE BYPASS CYCLING CLUTCH PRESSURE SWITCH USING JUMPER WIRE. (REFER TO GROUP 8, WIRING DIA- GRAMS) PRESSURES OK SYSTEM IS NORMAL CORRECT EVAPORATOR INLET GAUGE PRESSURE CORRECT COM- PRESSOR DISCHARGE GAUGE PRESSURE PRESSURES ABNORMAL EVAPORATOR PRESSURE LOWER THAN NORMAL COMPRESSOR DISCHARGE PRESSURE LOWER THAN NOR- MAL ORIFICE TUBE RESTRICTED OR PLUGGED EVAPORATOR RESTRICTED OR PLUGGED EVAPORATOR PRES- SURE SLIGHTLY HIGHER THAN NORMAL COMPRESSOR DISCHARGE PRESSURE HIGHER THAN NORMAL RESTRICTED CON- DENSOR. RESTRICTED DIS- CHARGE LINE. RADIA- TOR OVERHEATING. AIR IN SYSTEM. OVERCHARGED SYS- TEM. COOLING FAN INOP. SEE A/C PERFORMANCE (TEMPERATURE AND PRESSURE) CHART EVAPORATOR PRES- SURE SLIGHTLY HIGHER THAN NORMAL COMPRESSOR DISCHARGE PRESSURE LOWER THAN NOR- MAL DEFECTIVE COM- PRESSOR LOW CHARGE
ZG HEATING AND AIR CONDITIONING 24 - 13
DIAGNOSIS AND TESTING (Continued)
HEATER PERFORMANCE
PREPARATIONS
Revi ew the Servi ce Warni ngs and Precauti ons i n
the front of thi s group before performi ng the fol l ow-
i ng procedures.
Check the radi ator cool ant l evel , serpenti ne dri ve
bel t tensi on, and engi ne vacuum l i ne connecti ons.
Al so check the radi ator ai r fl ow and the radi ator fan
operati on. Start the engi ne and al l ow i t to warm up
to normal operati ng temperature.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WHEN THE ENGINE IS AT OPERATING TEMPERA-
TURE, PERSONAL INJURY MAY RESULT.
I f the vehi cl e has been operated recentl y, wai t fi f-
teen mi nutes or l onger before removi ng the radi ator
cap. Pl ace a rag over the cap and turn i t to the fi rst
safety stop. Al l ow any pressure to escape through the
overfl ow tube. When the cool i ng system pressure sta-
bi l i zes, remove the cap compl etel y.
MAXIMUM HEATER OUTPUT
Engi ne cool ant i s del i vered to the heater core
through two heater hoses. Wi th the engi ne i dl i ng at
normal operati ng temperature, set the temperature
control knob i n the ful l hot posi ti on, the mode control
knob i n the Fl oor posi ti on, and the bl ower motor
swi tch knob i n the Hi gh speed posi ti on. Usi ng a test
thermometer, check the ai r temperature comi ng from
the fl oor outl ets. Compare the ai r temperature read-
i ng to the Heater Temperature Reference chart (Fi g.
9).
I f the fl oor outl et ai r temperature i s l ow, refer to
Group 7 - Cool i ng System for the cool ant tempera-
ture speci fi cati ons. Both of the heater hoses shoul d
be hot to the touch. The cool ant return hose shoul d
be sl i ghtl y cool er than the suppl y hose. I f the cool ant
return hose i s much cool er than the suppl y hose,
l ocate and repai r the engi ne cool ant fl ow obstructi on
i n the heater system.
OBSTRUCTED COOLANT FLOW
Possi bl e l ocati ons or causes of obstructed cool ant
fl ow:
Pi nched or ki nked heater hoses.
I mproper heater hose routi ng.
Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons (refer to Group 7 -
Cool i ng System).
A pl ugged heater core.
I f proper cool ant fl ow through the heater system i s
veri fi ed, and outl et ai r temperature i s sti l l l ow, a
mechani cal probl em may exi st.
MECHANICAL PROBLEMS
Possi bl e l ocati ons or causes of i nsuffi ci ent heat:
An obstructed cowl ai r i ntake.
Obstructed heater system outl ets.
A bl end-ai r door not functi oni ng properl y.
TEMPERATURE CONTROL
I f the heater di scharge ai r temperature cannot be
adjusted wi th the temperature control knob on the
heater-A/C control panel , the fol l owi ng coul d requi re
servi ce:
The heater-A/C control panel .
The bl end ai r door actuator.
The wi re harness ci rcui ts for the heater-A/C con-
trol panel or the bl end ai r door actuator.
I mproper engi ne cool ant temperature.
VACUUM SYSTEM
Vacuum control i s used to operate the mode doors
i n the manual temperature control system heater-
A/C housi ng. Testi ng of the heater-A/C mode control
swi tch operati on wi l l determi ne i f the vacuum and
el ectri cal control s are functi oni ng. However, i t i s pos-
si bl e that a vacuum control system that operates per-
fectl y at engi ne i dl e (hi gh engi ne vacuum) may not
functi on properl y at hi gh engi ne speeds or l oads (l ow
engi ne vacuum). Thi s can be caused by l eaks i n the
vacuum system, or a faul ty vacuum check val ve.
A vacuum system test wi l l hel p to i denti fy the
source of poor vacuum system performance, or vac-
uum system l eaks. Before starti ng thi s test, stop the
engi ne and make certai n that the probl em i snt a di s-
connected vacuum suppl y tube at the engi ne i ntake
mani fol d or the vacuum reservoi r.
Use an adjustabl e vacuum test set (Speci al Tool
C-3707) and a sui tabl e vacuum pump to test the
heater-A/C vacuum control system. Wi th a fi nger
pl aced over the end of the vacuum test hose probe
(Fi g. 10), adjust the bl eed val ve on the test set gauge
to obtai n a vacuum of exactl y 27 kPa (8 i n. Hg.).
Rel ease and bl ock the end of the probe several ti mes
to veri fy that the vacuum readi ng returns to the
Minimum Heater
System
Ambient Temperature Floor Outlet
Temperature
Celsius Fahrenheit Celsius Fahrenheit
15.5 60 62.2 144
21.1 70 63.8 147
26.6 80 65.5 150
32.2 90 67.2 153
Fig. 9 Heater Temperature Reference
24 - 14 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
exact 27 kPa (8 i n. Hg.) setti ng. Otherwi se, a fal se
readi ng wi l l be obtai ned duri ng testi ng.
VACUUM CHECK VALVE
(1) Remove the vacuum check val ve. The val ve i s
l ocated i n the (bl ack) vacuum suppl y hose near the
engi ne i ntake mani fol d.
(2) Connect the test set vacuum suppl y hose to the
heater si de of the val ve. When connected to thi s si de
of the check val ve, no vacuum shoul d pass and the
test set gauge shoul d return to the 27 kPa (8 i n. Hg.)
setti ng. I f OK, go to step Step 3. I f not OK, repl ace
the faul ty val ve.
(3) Connect the test set vacuum suppl y hose to the
engi ne vacuum si de of the val ve. When connected to
thi s si de of the check val ve, vacuum shoul d fl ow
through the val ve wi thout restri cti on. I f not OK,
repl ace the faul ty val ve.
HEATER-A/C CONTROLS
(1) Connect the test set vacuum probe to the heat-
er-A/C vacuum suppl y (bl ack) hose i n the engi ne
compartment. Posi ti on the test set gauge so that i t
can be vi ewed from the passenger compartment.
(2) Pl ace the heater-A/C mode control knob i n each
mode, one at a ti me, and pause after each sel ecti on.
The test set gauge shoul d return to the 27 kPa (8 i n.
Hg.) setti ng shortl y after each sel ecti on i s made. I f
not OK, a component or vacuum l i ne i n the sel ected
modes ci rcui t has a l eak. See the procedure i n Locat-
i ng Vacuum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
LOCATING VACUUM LEAKS
(1) Di sconnect the vacuum connector from the
back of the heater-A/C mode control swi tch on the
control panel .
(2) Connect the test set vacuum hose probe to each
port i n the vacuum harness connector, one at a ti me,
and pause after each connecti on (Fi g. 11). The test
set gauge shoul d return to the 27 kPa (8 i n. Hg.) set-
ti ng shortl y after each connecti on i s made. I f OK,
repl ace the faul ty mode control swi tch. I f not OK, go
to Step 3.
(3) Determi ne the vacuum l i ne col or of the vacuum
ci rcui t that i s l eaki ng. To determi ne the vacuum l i ne
col ors, refer to the Vacuum Ci rcui ts chart (Fi g. 12).
(4) Di sconnect and pl ug the vacuum l i ne from the
component (fi tti ng, actuator, val ve, swi tch, or reser-
voi r) on the other end of the l eaki ng ci rcui t. I nstru-
ment panel di sassembl y or removal may be necessary
to gai n access to some components.
(5) Connect the test set hose or probe to the open
end of the l eaki ng ci rcui t. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each connecti on i s made. I f OK, repl ace the faul ty
di sconnected component. I f not OK, go to Step 6.
(6) To l ocate a l eak i n a vacuum l i ne, l eave one
end of the l i ne pl ugged and connect the test set hose
or probe to the other end. Run your fi ngers sl owl y
al ong the l i ne whi l e watchi ng the test set gauge. The
vacuum readi ng wi l l fl uctuate when your fi ngers con-
tact the source of the l eak. To repai r the vacuum
l i ne, cut out the l eaki ng secti on of the l i ne. Then,
i nsert the l oose ends of the l i ne i nto a sui tabl e l ength
of 3 mm (1/8-i nch) i nsi de di ameter rubber hose.
Fig. 10 Adjust Vacuum Test Bleed Valve
VACUUM PUMP TOOL C-4289 VACUUM TEST SET C-3707 BLEEDVALVE PROBE
Fig. 11 Vacuum Circuit Test
ZG HEATING AND AIR CONDITIONING 24 - 15
DIAGNOSIS AND TESTING (Continued)
ATC SYSTEM
The Automati c Temperature Control (ATC) control -
l er has a system sel f-di agnosti c mode. The control l er
i s capabl e of troubl eshooti ng each of i ts i nput and
output ci rcui ts. When the control l er detects a faul t
and pl aces i t i n memory, an Er i s momentari l y di s-
pl ayed i n the heater-A/C control panel vacuum fl uo-
rescent di spl ay area, but i t wi l l onl y be di spl ayed
once duri ng each i gni ti on cycl e. The ATC control l er i s
capabl e of three di fferent types of sel f-di agnosti c
tests, as fol l ows:
Faul t Code Tests
I nput Ci rcui t Tests
Output Ci rcui t/Actuator Tests
The i nformati on that fol l ows descri bes how to read
the sel f-di agnosti c di spl ay, how to enter the ATC con-
trol l er sel f-di agnosti c test mode, how to sel ect the
three sel f-di agnosti c test types, and how to perform
the three di fferent tests.
SELF-DIAGNOSTIC DISPLAY
I n the sel f-di agnosti c mode, the test i nformati on i s
di spl ayed i n the vacuum fl uorescent di spl ay area of
the heater-A/C control . The area of the di spl ay where
the temperature control comfort l evel i s normal l y di s-
pl ayed i s cal l ed the Test Sel ector. The Test Sel ector i s
used to di spl ay faul t codes, i denti fy the test mode,
and show the val ues of the ci rcui ts bei ng tested. The
fol l owi ng i nformati on descri bes how the val ues i n the
Test Sel ector di spl ay shoul d be i nterpreted.
(1) The Sel ect Test mode wi l l have onl y 00 di s-
pl ayed i n the Test Sel ector, and no sti ck man wi l l be
di spl ayed. Thi s i s the sel f-di agnosti c mode from
whi ch the vari ous tests may be sel ected.
(2) I f the sti ck man fl oor arrow (bottom) i s show-
i ng, the di spl ayed Test Sel ector val ue wi l l be a range
of numbers bel ow zero (Fi g. 13).
(3) I f the sti ck man appears, but no arrows are
showi ng, the di spl ayed Test Sel ector val ue wi l l be a
range of numbers between zero and ni nety-ni ne (Fi g.
14).
(4) I f the sti ck man panel arrow (mi ddl e) i s show-
i ng, the di spl ayed Test Sel ector val ue wi l l be a range
of numbers between 100 and 199 (Fi g. 15).
(5) I f the sti ck man panel (mi ddl e) and defrost
(top) arrows are showi ng, the di spl ayed Test Sel ector
Fig. 12 Vacuum Circuits
A RECIRC B DEF. F/D C PAN. DEF D VACUUM RES- ERVOIR VACUUM VENTED OFF
BI-LEVEL
PANEL RECIR- CULATING FLOOR/ DEFROST FLOOR DEFROST
Fig. 13 Test Selector Values Below Zero
TEST SELEC- TOR DISPLAY STICKMAN A/C BUTTON RECIRC BUTTON TEMPERATURE ROTARY CONTROL FLOOR ARROW
Fig. 14 Test Selector Values Between Zeroand
Ninety-Nine
TEST SELECTOR DISPLAY STICKMAN A/C BUTTON RECIRC BUTTON TEMPERATURE ROTARY CONTROL
24 - 16 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
val ue wi l l be a range of numbers between 200 and
255 (Fi g. 16).
(6) t any ti me duri ng the sel f-di agnosti c tests, you
may return to the Sel ect Test mode by turni ng the tem-
perature rotary control one cl i ck i n ei ther di recti on.
Agai n, the sti ck man and arrows are not shown i n the
Sel ect Test mode. At thi s poi nt, you have the opti on of
moni tori ng or testi ng another ci rcui t (Fi g. 17).
ENTERING THE ATC SELF-DIAGNOSTIC MODE
To enter the ATC sel f-di agnosti c mode, perform the
fol l owi ng:
(1) Depress the A/C and Reci rc buttons at the
same ti me and hol d. Rotate the rotary temperature
control knob cl ockwi se one cl i ck.
(2) I f you conti nue to hol d the A/C and Reci rc but-
tons depressed, you wi l l see al l of the di spl ay seg-
ments i l l umi nate. I f a segment fai l s to i l l umi nate,
the vacuum fl uorescent di spl ay i s faul ty.
(3) After vi ewi ng the segment test, rel ease the A/C
and Reci rc buttons. Thi s wi l l put the Test Sel ector
val ue at 00, and no sti ck man wi l l be di spl ayed. Thi s
i s the Sel ect Test mode. At thi s poi nt a number of
tests can be sel ected, however, the Faul t Code Test
shoul d be performed fi rst.
FAULT CODE TESTS
Faul t codes are two-di gi t numbers that i denti fy a
ci rcui t that i s mal functi oni ng. There are two di ffer-
ent ki nds of faul t codes.
1. Current Fault Codes - Current means the
faul t i s present ri ght now. There are two types of cur-
rent faul ts: i nput faul ts, and system faul ts.
2. Historical Fault Codes - Hi stori cal or stored
means the faul t occurred previ ousl y, but i s OK ri ght now.
A majori ty of hi stori cal faul t codes are caused by i nter-
mi ttent wi re harness or wi re harness connector probl ems.
NOTE: A battery disconnect will erase all faults stored
in Read Available Memory (RAM). It is recommended
that all faults be recorded before they are erased.
RETRIEVING FAULT CODES
(1) To begi n the Faul t Code Tests you must be i n
the Sel ect Test mode. Wi th 00 di spl ayed i n the Test
Sel ector and no sti ck man, push ei ther the A/C or
Reci rc button.
(2) The sti ck man wi l l appear i ndi cati ng you have
entered the Faul t Code Tests. The val ues di spl ayed
i n the Test Sel ector wi l l range from 00 to 64.
(3) Faul t codes wi l l appear and repeat i f there are
more than one. Record al l of the faul t codes, then see
the Current and Hi stori cal Faul t Code charts for the
descri pti ons. I f there are no faul t codes, the di spl ay
val ue remai ns at 00.
(4) I f a Faul t Code 25 or 29 i s di spl ayed, the ATC
control modul e must be repl aced before any further
testi ng i s performed.
(5) For more detai l ed i nformati on about a faul t
code, see the I nput Ci rcui t Tests or the Output Ci r-
cui t/Actuator Tests.
Fig. 15 Test Selector Values Between 100and 199
TEST SELECTOR DISPLAY PANEL ARROW STICKMAN A/C BUTTON RECIRC BUT- TON TEMPERATURE ROTARY CONTROL
Fig. 16 Test Selector Values Between 200and 255
DEFROST ARROW DISPLAY PANEL ARROW STICKMAN A/C BUT- TON RECIRC BUT- TON TEMPERATURE ROTARY CONTROL TEST SELEC- TOR
Fig. 17 Return to Select Test Mode
TEST SELEC- TOR DISPLAY A/C BUTTON RECIRC BUT- TON TEMPERATURE ROTARY CONTROL
ZG HEATING AND AIR CONDITIONING 24 - 17
DIAGNOSIS AND TESTING (Continued)
Fail Code/Description Circuit Description
00 = No Faults
01 = Circuit open In-Vehicle Temperature Sensor
02 = Circuit open Solar Sensor Input Circuit
03 = Circuit open Front Panel Blower/Fan Control Input
04 = Circuit open Front Panel Mode Control Input
05 = Circuit open Blend Air Door Feedback Circuit
06 = Circuit open Mode Door Feedback Circuit
07 = Feedback too high Blower/Fan Feedback Circuit
08 = Circuit shorted In-Vehicle Temperature Sensor
09 = Circuit shorted Solar Sensor Input Circuit
10 = Circuit shorted Front Panel Blower/Fan Control Input
11 = Circuit shorted Front Panel Mode Control Input
12 = Circuit shorted Blend Air Door Feedback Circuit
13 = Circuit shorted Mode Door Feedback Circuit
14 = Feedback too low Blower/Fan Feedback Circuit
15 = Door not responding Mode Door Feedback Circuit
16 = Door not responding Blend Air Door Actuator Drive Circuit
17 = Door travel range too small Mode Door Feedback Circuit
18 = Door travel range too large Mode Door Feedback Circuit
19 = Door travel range too small Blend Air Door Actuator Drive Circuit
20 = Door travel range too large Blend Air Door Actuator Drive Circuit
21 = Calibration data error Calibration and CPU Data
22 = BCM message missing Collision Detection C2D Bus Inputs
23 = PCM message Missing Collision Detection C2D Bus Inputs
24 = CPU error Calibration and CPU Data
25 = Reserved
26 = Reserved
27 = Reserved
Current Fault Codes
24 - 18 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
Fail Code/Description Circuit Description
28 = Circuit was open In-Vehicle Temperature Sensor
29 = Circuit was open Solar Sensor Input Circuit
30 = Circuit was open Front Panel Blower/Fan Control Input
31 = Circuit was open Front Panel Mode Control Input
32 = Circuit was open Blend Air Door Feedback Circuit
33 = Circuit was open Mode Door Feedback Circuit
34 = Feedback was too high Blower/Fan Feedback Circuit
35 = Circuit was shorted In-Vehicle Temperature Sensor
36 = Circuit was shorted Solar Sensor Input Circuit
37 = Circuit was shorted Front Panel Blower/Fan Control Input
38 = Circuit was shorted Front Panel Mode Control Input
39 = Circuit was shorted Blend Air Door Feedback Circuit
40 = Circuit was shorted Mode Door Feedback Circuit
41 = Feedback was too low Blower/Fan Feedback Circuit
42 = Door was not responding Mode Door Feedback Circuit
43 = Door was not responding Blend Air Door Actuator Drive Circuit
44 = Door travel range was too small Mode Door Feedback Circuit
45 = Door travel range was too large Mode Door Feedback Circuit
46 = Door travel range was too small Blend Air Door Actuator Drive Circuit
47 = Door travel range was too large Blend Air Door Actuator Drive Circuit
48 = Calibration data was in error Calibration and CPU Data
49 = BCM message was missing Collision Detection C2D Bus Inputs
50 = PCM message was Missing Collision Detection C2D Bus Inputs
51 = CPU was in error Calibration and CPU Data
52 = Reserved
53 = Reserved
54 = Reserved
Historical Fault Codes
ZG HEATING AND AIR CONDITIONING 24 - 19
DIAGNOSIS AND TESTING (Continued)
CLEARING FAULT CODES
Current faul ts are cl eared whenever the probl em
goes away. To cl ear a hi stori cal faul t, depress and
hol d ei ther the A/C or Reci rc button for at l east three
seconds. The faul ts have been cl eared when two hor-
i zontal bars appear i n the di spl ay.
INPUT CIRCUIT TESTS
I n the I nput Ci rcui t Test mode, the status of i nput
ci rcui ts can be vi ewed and moni tored. I f a fai l ure
occurs wi thi n an i nput ci rcui t the control l er wi l l di s-
pl ay a ? for unknown val ues, OC for an open ci r-
cui t, or SC for a short ci rcui t.
(1) To begi n the I nput Ci rcui t Tests you must be i n
the Sel ect Test mode.
(2) Wi th 00 di spl ayed i n the Test Sel ector and no
sti ck man, turn the rotary temperature control knob
unti l the test number you are l ooki ng for appears i n
the Test Sel ector di spl ay. See the Ci rcui t Testi ng
charts for a l i sti ng of the test numbers, test i tems,
test types, system tested, and di spl ayed val ues.
(3) To see the ci rcui t i nput val ues, depress the A/C
or Reci rc button. The val ues di spl ayed wi l l represent
the i nput seen by the ATC control l er.
OUTPUT CIRCUIT/ACTUATOR TESTS
I n the Output Ci rcui t/Actuator Test mode, the out-
put ci rcui ts can be vi ewed, moni tored, overri dden,
and tested. I f a fai l ure occurs i n an output ci rcui t,
test the ci rcui t by overri di ng the system. Test the
actuator through i ts ful l range of operati on. When
the overri de control has been acti vated, the di spl ay
wi l l be fl ashi ng. The Test Sel ector wi l l di spl ay feed-
back i nformati on about the output ci rcui t bei ng
tested.
(1) To begi n the Output Ci rcui t/Actuator Tests you
must be i n the Sel ect Test mode.
(2) Wi th 00 di spl ayed i n the Test Sel ector and no
sti ck man, turn the rotary temperature control knob
unti l the test number you are l ooki ng for appears i n
the Test Sel ector di spl ay. See the Ci rcui t Testi ng
charts for a l i sti ng of the test numbers, test i tems,
test types, system tested, and di spl ayed val ues.
(3) To see the output val ue, depress the A/C or
Reci rc button. The val ues di spl ayed wi l l represent
the output from the ATC control l er.
(4) To enter the actuator test, depress the A/C or
Reci rc button. The di spl ay wi l l bl i nk, i ndi cati ng you
are i n the actuator test mode. Manual tests are those
i n whi ch you wi l l have to depress and hol d the A/C or
Reci rc button to control the output. Automati c tests
are those i n whi ch you wi l l have to depress the A/C
or Reci rc button once to generate the output.
24 - 20 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
Test
No.
Test
Item
Test
Type
System
Tested
Displayed
Values
01 Blower Control Switch
(A/D)
I Blower System ? OC SC 00-255
02 Blower Feedback I Blower System ? 00-255
03 Blower Speed O/A Blower System 00-255
04 Hi Blower Relay O/A Blower System 00=OFF 01 = ON
05 Mode Control A/D I Mode Door System OC SC 00-255
06 Mode Door Feedback I Mode Door System OC SC 00-255
07 Panel Stop I Mode Door System ? 00-255
If ? is displayed, activate Mode 11 to
find panel stop position.
08 Defrost Stop I Mode Door System ? 00-255
If ? is displayed, activate Mode 11 to
find defrost stop position.
09 A/C Request O/A A/C System 00 = OFF 01 = ON
10 Mode Door Position O/A Mode Door System 00-255
It is possible to command the door
position beyond the stops.
The motor will try to move there.
11 Mode Motor O/A Mode Door System Pressing A/C or RECIRC button for 3
sec. begins reinitalization.
00 = searching for panel stop
01 = searching for defrost stop
02 = moving toward panel
03 = moving toward defrost
04 = in position
05 = stalled moving toward panel
06 = stalled moving toward defrost
07 = feedback error
12 Mode Motor Drive
Lines
O Mode Door System 00 = stopped (lines low)
01 = toward defrost
02 = toward panel
03 = stopped (lines high)
13 Recirc Door O/A Recirc Door System 00 = continuous operation (lines
grounded)
01 = fresh
02 = recirc.
03 = stopped (lines open)
14 In-Vehicle Temp. A/D I Temperature Inputs OC SC 00-255
15 Blend Door Feedback I Blend Door System OC SC 00-255
16 Blend Door Cold Stop I Blend Door System ? 00-255
17 Blend Door Hot Stop I Blend Door System ? 00-255
Circuit Testing
ZG HEATING AND AIR CONDITIONING 24 - 21
DIAGNOSIS AND TESTING (Continued)
Test
No.
Test
Item
Test
Type
System
Tested
Displayed
Values
18 In-Vehicle Temperature I Temperature Inputs OC SC -40 to +60 C
(-40 to + 140 F)
19 Ambient Sensor I CCD -40 to + 60 C
(-40 to +140 F)
20 Solar Sensor A/D I Sun Intensity Input OC SC 00-255
21 Engine Coolant I CCD ? -40 to + 185 C
(-40 to +260 F)
22 Vehicle Speed
(MPH/KPM)
I CCD ? 00-255
23 Engine RPM (x100) I CCD 00-82
24 Blend Door Motor O/A Blend Door System Pressing A/C or RECIRC button for 3
sec. begins reinitialization.
00 = searching for hot stop
01 = searching for cold stop
02 = moving to warmer
03 = moving to cooler
04 = in position
05 = stalled moving to warmer
06 = stalled moving to cooler
07 = feedback error
25 Blend Door Motor O/A Blend Door System 00-255
It is possible to command the door
position beyond the stops. The motor
will try to move there.
26 Blend Door Motor
Lines
O/A Blend Door System 00 = stopped (lines low)
01 = toward cold
02 = toward hot
03 = stopped (lines high)
27 Lights On I Headlight Switch 00 = OFF 01 = ON
28 Dimming I PWD System ? 00-255
29 Dimming Level O/A Dimming System ? 00-255
30 ROM & EEPROM 00 = FF
31 ROM & EEPROM 00 = FF
32 ROM & EEPROM 00 = FF
33 ROM & EEPROM 00 = FF
34 ROM & EEPROM 00 = FF
35 ROM & EEPROM 00 = FF
36 ROM & EEPROM 00 = FF
37 ROM & EEPROM 00 = FF
Circuit Testing (cont.)
24 - 22 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
Blend Air Door Actuator Drive Circuit
ATC CONTROL MODULE BLEND AIR DOOR MOTOR WORM GEAR MOVES WIPER ARM BLEND AIR BLEND FEEDBACK VREF BLEND AIR +
Mode Door Actuator Drive Circuit
ATC CONTROL MODULE MODE DOOR MOTOR WORM GEAR MOVES WIPER ARM MODE VREF BLEND FEED- BACK MODE +
Air Inlet/Recirc Door Actuator DriveCircuit
ATC CONTROL MODULE AIR INLET/RECIRC DOOR MOTOR AIR INLET RECIRC IGNITION
Front Panel Mode Control Circuit
ATC CONTROL MODULE FRONT PANEL MODE CONTROL (POTENTI- OMETER) GROUND
A/D
Front Panel Blower/Fan Control Circuit
ATC CONTROL MODULE FRONT PANEL BLOWER/FAN CON- TROL (POTENTIOM- ETER) GROUND
A/D
ZG HEATING AND AIR CONDITIONING 24 - 23
DIAGNOSIS AND TESTING (Continued)
Solar Sensor Circuit
ATC CONTROL MODULE SUNLOAD SIGNAL SENSOR/ACTUATOR RETURN SOLAR SENSOR
In-Vehicle Temperature Sensor Circuit
ATC CONTROL MODULE IN-VEHICLE SENSOR SIG- NAL COMMON RETURN IN-VEHICLE TEMPERATURE SENSOR
Calibration and CPU Data
ATC CONTROL MODULE WATCHDOG CIRCUIT MICROPRO- CESSOR (CPU) ACTUATOR DRIV- ERS ACTUATORS COLLAGE SENSOR INPUTS CCD BUS CHIP
POWERTRAIN
CONTROL
MODULE
24 - 24 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
BLOWER MOTOR
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams. Possi bl e causes of an i noperati ve
bl ower motor i ncl ude:
Faul ty fuse
Faul ty bl ower motor ground ci rcui t wi re har-
nesses or connectors
Faul ty bl ower motor resi stor (manual tempera-
ture control )
Faul ty bl ower motor power modul e (ATC)
Faul ty bl ower motor swi tch
Faul ty heater-A/C mode control swi tch
Faul ty bl ower motor feed ci rcui t wi re harnesses
or connectors
Faul ty bl ower motor.
Possi bl e causes of the bl ower motor not operati ng
i n al l speeds i ncl ude:
Faul ty fuse
Faul ty bl ower motor swi tch
Faul ty bl ower motor resi stor (manual tempera-
ture control )
Faul ty bl ower motor power modul e (ATC)
Faul ty hi gh speed bl ower motor rel ay (ATC)
Faul ty ATC control l er
Faul ty bl ower motor ci rcui t wi re harnesses or
connectors.
VIBRATION
Possi bl e causes of bl ower motor vi brati on i ncl ude:
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower wheel out of bal ance or bent
Bl ower motor faul ty.
NOISE
To veri fy that the bl ower i s the source of the noi se,
unpl ug the bl ower motor wi re harness connector and
operate the heater-A/C system. I f the noi se goes
away, possi bl e causes i ncl ude:
Forei gn materi al i n the heater-A/C housi ng
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower motor faul ty.
BLOWER MOTOR RESISTOR
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
To test the bl ower motor resi stor, unpl ug the resi s-
tor wi re harness connector. Each bl ower motor swi tch
i nput termi nal on the resi stor must have conti nui ty
to the resi stor output termi nal , whi ch i s connected to
the ci rcui t goi ng to the bl ower motor. I f the bl ower
motor resi stor conti nui ty does not check OK, repl ace
the faul ty resi stor.
BLOWER MOTOR SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams. The bl ower motor swi tch i s onl y ser-
vi ced as a part of the heater-onl y or heater-A/C
control assembl y.
(1) Turn the i gni ti on swi tch to the Off posi ti on.
Remove the heater-A/C control from the i nstrument
panel . Check for conti nui ty between the ground ci r-
cui t cavi ty of the control wi re harness connector and
a good ground. There shoul d be conti nui ty. I f OK, go
to Step 2. I f not OK, repai r the open ci rcui t to ground
as requi red.
(2) Wi th the heater-A/C control wi re harness con-
nector unpl ugged, pl ace the mode control swi tch knob
i n any posi ti on except the Off posi ti on. Check for con-
ti nui ty between the ground ci rcui t termi nal and each
of the bl ower motor dri ver ci rcui t termi nal s of the
control as you move the bl ower swi tch to each of the
four speed posi ti ons. There shoul d be conti nui ty at
each dri ver ci rcui t termi nal i n onl y one bl ower motor
swi tch speed posi ti on. I f OK, test and repai r the
bl ower dri ver ci rcui ts between the control connector
and the bl ower motor resi stor as requi red. I f not OK,
repl ace the faul ty heater-A/C control uni t.
COMPRESSOR
When i nvesti gati ng an ai r condi ti oni ng rel ated
noi se, you must fi rst know the condi ti ons under
whi ch the noi se occurs. These condi ti ons i ncl ude:
weather, vehi cl e speed, transmi ssi on i n gear or neu-
tral , engi ne temperature, and any other speci al con-
di ti ons.
Noi ses that devel op duri ng ai r condi ti oni ng opera-
ti on can often be mi sl eadi ng. For exampl e: What
sounds l i ke a fai l ed front beari ng or connecti ng rod,
may be caused by l oose bol ts, nuts, mounti ng brack-
ets, or a l oose cl utch assembl y. Veri fy serpenti ne
dri ve bel t tensi on. I mproper bel t tensi on can cause a
mi sl eadi ng noi se when the compressor i s engaged.
The noi se may not occur when the compressor i s di s-
engaged.
Dri ve bel ts are speed sensi ti ve. At di fferent engi ne
speeds and dependi ng upon bel t tensi on, bel ts can
devel op noi ses that are mi staken for a compressor
noi se.
(1) Sel ect a qui et area for testi ng. Dupl i cate the
compl ai nt condi ti ons as much as possi bl e. Swi tch the
compressor on and off several ti mes to cl earl y i den-
ti fy the compressor noi se. Li sten to the compressor
cl utch whi l e engaged and di sengaged.
(2) To dupl i cate a hi gh-ambi ent temperature condi -
ti on (hi gh head pressure), restri ct the ai r fl ow
through the condenser. I nstal l a mani fol d gauge set
to make sure that the di scharge pressure does not
exceed 2070 kPa (300 psi ).
ZG HEATING AND AIR CONDITIONING 24 - 25
DIAGNOSIS AND TESTING (Continued)
(3) Ti ghten al l compressor mounti ng bol ts, the
cl utch mounti ng nut, the cl utch coi l mounti ng screw
or nut, and the serpenti ne dri ve bel t to the correct
speci fi cati ons.
(4) Check the refri gerant system pl umbi ng for rub-
bi ng or i nterference, whi ch can cause unusual noi ses.
(5) Check the refri gerant system charge. See the
Chargi ng Refri gerant System procedure i n thi s
group.
(6) Check the compressor noi se as i n Step 1.
(7) I f the noi se sti l l exi sts, l oosen the compressor
mounti ng bol ts and ti ghten agai n. Repeat Step 1.
(8) I f the noi se conti nues, repl ace the compressor
and repeat Step 1.
COMPRESSOR CLUTCH COIL
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams. The battery must be ful l y-charged
before performi ng the fol l owi ng tests. Refer to Group
8A - Battery for more i nformati on.
(1) Connect an ammeter (0 to 10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0 to 20 vol t scal e) wi th cl i p-type l eads for measuri ng
the vol tage across the battery and the compressor
cl utch coi l .
(2) Wi th the heater-A/C mode control swi tch i n any
A/C mode, and the bl ower motor swi tch i n the l owest
speed posi ti on, start the engi ne and run i t at normal
i dl e.
(3) The compressor cl utch coi l vol tage shoul d read
wi thi n two vol ts of the battery vol tage. I f there i s
vol tage at the cl utch coi l , but the readi ng i s not
wi thi n two vol ts of the battery vol tage, test the
cl utch coi l feed ci rcui t for excessi ve vol tage drop and
repai r as requi red. I f there i s no vol tage readi ng at
the cl utch coi l , refer to the proper Powertrai n Di ag-
nosti c Procedures manual for testi ng of the compres-
sor cl utch ci rcui t. The fol l owi ng components must be
checked and repai red as requi red before you can com-
pl ete testi ng of the cl utch coi l :
Fuses i n the juncti on bl ock and the Power Di s-
tri buti on Center
Heater-A/C mode control swi tch
Compressor cl utch rel ay
Hi gh pressure cut-off swi tch
Low pressure cycl i ng cl utch swi tch
Powertrai n Control Modul e.
(4) The compressor cl utch coi l i s acceptabl e i f the
current draw measured at the cl utch coi l i s 2.0 to 3.9
amperes wi th el ectri cal system vol tage at 11.5 to 12.5
vol ts. Thi s shoul d onl y be checked wi th the work
area temperature at 21 C (70 F). I f system vol tage
i s more than 12.5 vol ts, add el ectri cal l oads by turn-
i ng on el ectri cal accessori es unti l the system vol tage
drops bel ow 12.5 vol ts.
(a) I f the cl utch coi l current readi ng i s 4
amperes or more, the coi l i s shorted and shoul d be
repl aced.
(b) I f the cl utch coi l current readi ng i s zero, the
coi l i s open and shoul d be repl aced.
COMPRESSOR CLUTCH RELAY
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC). Refer to the PDC l abel for
rel ay i denti fi cati on and l ocati on. Remove the rel ay
from the PDC to perform the fol l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Rel ay Ci rcui t Test procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to fused battery feed. There shoul d be bat-
tery vol tage at the cavi ty for rel ay termi nal 30 at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the PDC fuse as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s not
used i n thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the compressor cl utch coi l . There shoul d
Compressor Clutch Relay
TERMINAL LEGEND NUMBER IDENTIFICATION COMMON FEED
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
24 - 26 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
be conti nui ty between thi s cavi ty and the A/C com-
pressor cl utch rel ay output ci rcui t cavi ty of the com-
pressor cl utch coi l wi re harness connector. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t as
requi red.
(4) The rel ay coi l battery termi nal (86) i s con-
nected to the fused i gni ti on swi tch output (run/start)
ci rcui t. There shoul d be battery vol tage at the cavi ty
for rel ay termi nal 86 wi th the i gni ti on swi tch i n the
On posi ti on. I f OK, go to Step 5. I f not OK, repai r the
open ci rcui t to the juncti on bl ock as requi red.
(5) The coi l ground termi nal cavi ty (85) i s swi tched
to ground through the Powertrai n Control Modul e
(PCM). There shoul d be conti nui ty between thi s cav-
i ty and the A/C compressor cl utch rel ay control ci r-
cui t cavi ty of the PCM wi re harness connector at al l
ti mes. I f not OK, repai r the open ci rcui t as requi red.
HIGH PRESSURE CUT-OFF SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
(1) Veri fy that the refri gerant system i s properl y
charged.
(2) Di sconnect and i sol ate the battery negati ve
cabl e.
(3) Unpl ug the hi gh pressure swi tch wi re harness
connector and test for conti nui ty between the swi tch
termi nal s. There shoul d be conti nui ty. I f OK, refer to
the wi ri ng di agrams and repai r the ci rcui ts as
requi red. I f not OK, repl ace the faul ty swi tch.
HIGH SPEED BLOWER MOTOR RELAY
RELAY TEST
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams. Remove the rel ay from i ts wi re har-
ness connector as descri bed i n thi s group to perform
the fol l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Rel ay Ci rcui t Test i n thi s
group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams.
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the Power Di stri buti on Center (PDC) fuse
as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the bl ower motor when the rel ay i s energi zed by
the ATC control l er. There shoul d be conti nui ty
between the cavi ty for rel ay termi nal 87 and the hi gh
speed bl ower motor rel ay si gnal ci rcui t cavi ty of the
bl ower motor wi re harness connector at al l ti mes. I f
OK, go to Step 4. I f not OK, repai r the open ci rcui t to
the bl ower motor as requi red.
(4) The coi l battery termi nal (86) i s connected to
battery vol tage and shoul d be hot at al l ti mes. I f OK,
go to Step 5. I f not OK, repai r the open ci rcui t to the
PDC fuse as requi red.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. I t i s grounded by the
ATC control l er when the bl ower swi tch i s pl aced i n
the manual Hi gh bl ower speed posi ti on and/or when
the ATC control l er senses the need for Hi gh bl ower
speed wi th the bl ower swi tch i n the Hi Auto posi ti on.
There shoul d be conti nui ty between the cavi ty for
rel ay termi nal 85 and the hi gh speed bl ower motor
rel ay control ci rcui t cavi ty of the ATC control l er wi re
harness connector at al l ti mes. I f OK, see the ATC
System tests i n thi s group. I f not OK, repai r the open
ci rcui t as requi red.
LOW PRESSURE CYCLING CLUTCH SWITCH
Veri fy that the refri gerant system has the correct
refri gerant charge. For ci rcui t descri pti ons and di a-
High Speed Blower Motor Relay
RELAY TERMINALS RELAY CAVITIES
ZG HEATING AND AIR CONDITIONING 24 - 27
DIAGNOSIS AND TESTING (Continued)
grams, refer to 8W-42 - Ai r Condi ti oni ng/Heater i n
Group 8W - Wi ri ng Di agrams.
(1) Unpl ug the l ow pressure cycl i ng cl utch swi tch
wi re harness connector from the swi tch on the accu-
mul ator, and i nstal l a jumper wi re between the two
connector cavi ti es.
(2) Connect a mani fol d gauge set to the refri gerant
system servi ce ports.
(3) Pl ace the heater-A/C mode control swi tch knob
i n any A/C posi ti on and start the engi ne.
(4) Check the conti nui ty between the two termi -
nal s of the l ow pressure swi tch. There shoul d be con-
ti nui ty wi th a sucti on pressure readi ng of 296 kPa
(43 psi ) or above, and no conti nui ty wi th a sucti on
pressure readi ng of 172 kPa (25 psi ) or bel ow. I f OK,
test and repai r the compressor cl utch control ci rcui t
as requi red. I f not OK, repl ace the faul ty swi tch.
REFRIGERANT SYSTEM LEAKS
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
LEAK TESTING THE SYSTEM.
I f the ai r condi ti oni ng system i s not cool i ng prop-
erl y, determi ne i f the refri gerant system i s ful l y-
charged. See A/C Performance i n thi s group. I f the
refri gerant system i s l ow or empty, a l eak at a l i ne,
fi tti ng, or component seal i s l i kel y. Fi tti ngs, l i nes, or
components that appear to be oi l y i ndi cate a possi bl e
refri gerant l eak. To detect a l eak i n the refri gerant
system, perform one of the fol l owi ng procedures:
SYSTEM EMPTY
(1) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group.
(2) Connect and di spense 0.283 kPa (0.6 l bs. or 10
oz.) of R-134a refri gerant i nto the evacuated refri ger-
ant system. See Refri gerant System Charge i n thi s
group.
(3) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(4) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Move the
l eak detector probe sl owl y al ong the bottom si de of
al l l i nes and fi tti ngs, because R-134a i s heavi er than
ai r.
(5) To i nspect the evaporator coi l for l eaks, i nsert
the l eak detector probe i nto the center panel outl et.
Set the bl ower motor swi tch to the l owest speed (A/C)
posi ti on, and the mode control swi tch i n the Reci rcu-
l ati on mode.
SYSTEM LOW
(1) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(2) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run wi th the ai r condi ti oni ng system on
for fi ve mi nutes.
(3) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Move the
l eak detector probe sl owl y al ong the bottom si de of
al l l i nes and fi tti ngs, because R-134a i s heavi er than
ai r.
(4) To i nspect the evaporator coi l for l eaks, i nsert
the l eak detector probe i nto the center panel outl et.
Set the bl ower motor swi tch to the l owest speed (A/C)
posi ti on, and the mode control swi tch i n the Reci rcu-
l ati on mode.
SERVICE PROCEDURES
REFRIGERANT RECOVERY
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
RECOVERING REFRIGERANT.
R-134a refri gerant i s a hydrofl uorocarbon (HFC)
that does not contai n chl ori ne. A R-134a refri gerant
recovery/recycl i ng stati on that meets SAE Standard
J2210 must be used to recover the refri gerant. Refer
to the operati ng i nstructi ons provi ded wi th the equi p-
ment for proper operati on.
REFRIGERANT SYSTEM EVACUATE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
EVACUATING THE SYSTEM.
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be charged. Moi sture and ai r mi xed wi th the
refri gerant wi l l rai se the compressor head pressure
above acceptabl e operati ng l evel s. Thi s wi l l reduce
the performance of the ai r condi ti oner and damage
the compressor. Evacuati ng wi l l boi l the moi sture out
of the refri gerant system at near room temperature.
To evacuate the refri gerant system, use the fol l owi ng
procedure:
(1) Connect a sui tabl e chargi ng stati on and mani -
fol d gauge set to the vehi cl e.
(2) Open the l ow and hi gh si de val ves and start
the vacuum pump. When the sucti on gauge reads 88
kPa (26 i n. Hg.) vacuum or greater, cl ose al l of the
val ves and turn off the vacuum pump. I f the system
fai l s to reach the speci fi ed vacuum, the system has a
l eak that must be corrected. I f the system mai ntai ns
the speci fi ed vacuum for fi ve mi nutes, restart the
24 - 28 HEATING AND AIR CONDITIONING ZG
DIAGNOSIS AND TESTING (Continued)
vacuum pump. Then open the sucti on and di scharge
val ves and evacuate an addi ti onal ten mi nutes.
(3) Cl ose al l of the val ves. Turn off and di sconnect
the vacuum pump.
(4) The refri gerant system i s now ready to be
charged wi th refri gerant.
REFRIGERANT SYSTEM CHARGE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
CHARGING THE REFRIGERANT SYSTEM.
After the system has been tested for l eaks and
evacuated, a refri gerant charge can be i njected i nto
the system. See Refri gerant Charge Capaci ty for the
proper amount of the refri gerant charge. Charge the
system usi ng a recovery/recycl i ng/chargi ng stati on
approved for R-134a refri gerant. Thi s devi ce must
meet SAE Standard J2210. Refer to the i nstructi ons
provi ded wi th the equi pment for proper operati on.
REFRIGERANT CHARGE CAPACITY
The R-134a system charge capaci ty i s 0.8 kg (1.75
l bs.).
PARTIAL CHARGE METHOD
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
CHARGING THE REFRIGERANT SYSTEM.
The parti al charge method i s used to add a parti al
charge to a system that i s l ow on refri gerant. To per-
form thi s procedure the evaporator i nl et and outl et
tube temperatures are measured. The temperature
di fference i s measured wi th a temperature meter
wi th one or two cl amp-on thermocoupl e probes. The
di fference between the evaporator i nl et and outl et
tube temperatures wi l l determi ne the amount of
refri gerant needed.
Before addi ng a parti al charge, check for refri ger-
ant system l eaks. See Refri gerant System Leaks i n
thi s group for the procedures. I f a l eak i s found,
make the necessary repai rs before attempti ng a ful l
or parti al refri gerant system charge.
(1) Attach a mani fol d gauge set to the servi ce
ports.
(2) Attach the two cl amp-on thermocoupl e probes
to the i nl et and outl et tubes of the evaporator coi l .
a. I f a si ngl e thermocoupl e probe i s used, attach
the probe to the evaporator i nl et tube just before the
col l ar of the refri gerant l i ne connector fi tti ng. The
probe must make contact wi th the bottom surface of
the i nl et tube.
b. I f dual thermocoupl e probes are used, attach
probe 1 to the evaporator i nl et tube, and probe 2 to
the evaporator outl et tube. Attach both probes to the
tubes just before the col l ar of the refri gerant l i ne
connector fi tti ngs. The probes must make contact
wi th the bottom surfaces of the i nl et and outl et
tubes.
(3) Open al l of the wi ndows or doors of the passen-
ger compartment. Set the ai r condi ti oni ng control s to
A/C, Panel , Reci rc (temperature control knob i n the
ful l cool posi ti on) and the bl ower motor swi tch on
Hi gh.
(4) Start the engi ne and hol d the engi ne i dl e speed
at 1,000 rpm. Al l ow the engi ne to warm up to normal
operati ng temperature.
(5) The compressor cl utch may cycl e, dependi ng
upon ambi ent temperature, humi di ty, and the refri g-
erant system charge l evel . I f the compressor cl utch
cycl es, unpl ug the wi re harness connector from the
l ow pressure cycl i ng cl utch swi tch on the accumul a-
tor. I nstal l a jumper wi re between the two cavi ti es of
the swi tch wi re harness connector.
(6) Hol d the engi ne i dl e speed at 1,000 rpm.
(7) Al l ow three to fi ve mi nutes for the refri gerant
system to stabi l i ze, then record the temperatures of
the evaporator i nl et and outl et tubes.
c. I f a si ngl e probe i s used, record the temperature
of the i nl et tube. Then remove the probe from the
i nl et tube and attach i t to the outl et tube just before
the col l ar of the refri gerant l i ne connector fi tti ng.
The probe must make contact wi th the bottom sur-
face of the tube. Al l ow the thermocoupl e and meter
ti me to stabi l i ze, then record the temperature of the
outl et tube. Subtract the i nl et tube temperature
readi ng from the outl et tube temperature readi ng.
d. I f dual probes are used, record the temperatures
of both the i nl et and outl et tubes. Then subtract the
i nl et tube temperature readi ng from the outl et tube
temperature readi ng.
(8) See the Low Charge Determi nati on chart to
determi ne the addi ti onal charge requi red. I f the mea-
sured temperature di fferenti al i s hi gher than 22 C
to 26 C (40 F to 47 F), add 0.4 kg (14 oz.) of refri g-
erant.
(9) Al l ow three to fi ve mi nutes for the refri gerant
system to stabi l i ze, then take a second set of thermo-
coupl e measurements. Record the temperature di ffer-
ence and see the Low Charge Determi nati on chart
(Fi g. 18) to determi ne i f an addi ti onal charge i s
requi red.
(10) Record the compressor di scharge pressure. I f
the readi ng i s hi gher than the pressure shown i n the
Compressor Di scharge Pressure chart (Fi g. 19), the
system coul d be overcharged. I f the readi ng i s equal
to, or l ower, than the pressure shown i n the chart,
conti nue wi th thi s procedure.
(11) EXAMPLE: The ambi ent temperature i s 21
C (70 F). The evaporator i nl et tube temperature i s
ZG HEATING AND AIR CONDITIONING 24 - 29
SERVICE PROCEDURES (Continued)
12 C (54 F) and the evaporator outl et tube temper-
ature i s 10 C (50 F). Subtract the i nl et tube tem-
perature from the outl et tube temperature. The
di fference i s -2 C (-4 F). Wi th a -2 C (-4 F) tem-
perature di fferenti al at 21 C (70 F) ambi ent tem-
perature, the system i s ful l y charged.
(12) Add enough refri gerant to bri ng the refri ger-
ant system up to a ful l charge.
(13) Remove the jumper wi re from the l ow pres-
sure cycl i ng cl utch swi tch wi re harness connector
and pl ug the connector back i nto the swi tch.
REFRIGERANT OIL LEVEL
When an ai r condi ti oni ng system i s assembl ed at
the factory, al l components (except the compressor)
are refri gerant oi l free. After the system has been
charged and operated, the oi l i n the compressor i s
di spersed throughout the refri gerant system. The
accumul ator, evaporator, condenser, and compressor
wi l l each retai n a si gni fi cant amount of oi l .
I t i s i mportant to have the correct amount of oi l i n
the refri gerant system. Thi s wi l l ensure proper l ubri -
cati on of the compressor. Too l i ttl e oi l wi l l resul t i n
damage to the compressor. Too much oi l wi l l reduce
the cool i ng capaci ty of the system.
I t wi l l not be necessary to check the oi l l evel i n the
compressor or to add oi l , unl ess there has been an oi l
l oss. Thi s may be due to a rupture or l eak from a
refri gerant l i ne, a compressor shaft seal , an evapora-
tor, or a condenser. I f a rupture occurs, add 30 ml (1
ounce) of oi l to the system after the repai r has been
made. Oi l l oss at a l eak poi nt wi l l be evi dent by the
presence of a wet, shi ny surface around the l eak.
Refri gerant oi l must be added when a accumul ator,
evaporator, or condenser are repl aced. See the Refri g-
erant Oi l Capaci ti es chart. When a compressor i s
repl aced, the oi l must be drai ned from the ol d com-
pressor and measured. Drai n al l the oi l from the new
compressor, then fi l l the new compressor wi th the
same amount of oi l that was drai ned out of the ol d
compressor.
Evaporator Outlet and Inlet Temperature Differential
If Outlet is WARMER than Inlet, temperature differential is plus (+).
If Outlet is COLDER than Inlet, temperature differential is minus (-).
See the example in the Refrigerant Charge Check (Alternative Method).
Added Amount
of R134a to
Properly Charge
A/C System
Ambient Temperature
21C
(70F)
21C
(80F)
32C
(90F)
38C
(100F)
43C
(100F)
Differential Temperature
0.90 lbs.
(14 oz.)
+22C
(+40F)
+23C
(+42F)
+24C
(+43F)
+25C
(+45F)
+26C
(+47F)
0.75 lbs.
(12 oz.)
+12C
(+12F)
+12C
(+23F)
+13C
(+24F)
+15C
(+26F)
+16C
(+28F)
0.60 lbs.
(10 oz.)
+4C
(+8F)
+5C
(+9F)
+6C
(+10F)
+7C
(+12F)
+8C
(+13F)
0.50 lbs.
(8 oz.)
0C
(0F)
+0C
(+1F)
+1C
(+2F)
+2C
(+3F)
+3C
(+4F)
0.40 lbs.
(6 oz.)
-1C
(2F)
-1C
(1F)
+0C
(0F)
0C
(0F)
0C
(0F)
Recommended
Charge
-2 to -6C
(3 to - 10F)
Fig. 18 Low Charge Determination
Ambient 16C 21C 27C 32C 38C 43C
Temperature (60F) (70F) (80F) (90F) (100F) (110F)
Compressor 1515 kPa 1655 kPa 1790 kPa 2070 kPa 2345 kPa 2690 kPa
Discharge
Pressure (220 psi) (240 psi) (260 psi) (300 psi) (340 psi) (390 psi)
Fig. 19 Compressor Discharge Pressure
24 - 30 HEATING AND AIR CONDITIONING ZG
SERVICE PROCEDURES (Continued)
REMOVAL AND INSTALLATION
REFRIGERANT LINE COUPLER
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(2) Remove the secondary cl i p from the coupl er. Fi t
the appropri ate spri ng l ock refri gerant l i ne coupl er
tool from the A/C Tool Ki t (Speci al Tool 6125) to the
coupl er (Fi g. 20).
(3) Cl ose the tool and push i t i nto the open si de of
the cage to expand the garter spri ng and rel ease the
femal e fi tti ng.
NOTE: The garter spring may not release if the tool
is cocked while pushing it into the cage opening.
(4) After the garter spri ng i s expanded, pul l the
fi tti ngs apart wi thi n the tool .
(5) Remove the tool from the di sconnected coupl er.
(6) Separate the two ends of the coupl er.
INSTALLATION
(1) Check to ensure that the garter spri ng i s i n the
cage of the mal e coupl er fi tti ng. I f the garter spri ng
i s mi ssi ng, i nstal l a new spri ng by pushi ng i t i nto the
cage openi ng. I f the garter spri ng i s damaged,
remove i t from the cage wi th a smal l wi re hook (DO
NOT use a screwdri ver) and i nstal l a new garter
spri ng.
(2) Cl ean any di rt or forei gn materi al from both
hal ves of the coupl i ng.
(3) I nstal l new O-ri ngs on the mal e fi tti ng.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-ring may allow the con-
nection to leak intermittently during vehicle
operation.
(4) Lubri cate the mal e fi tti ng and O-ri ng, and the
i nsi de of the femal e fi tti ng wi th cl ean R-134a refri g-
erant oi l . Use onl y refri gerant oi l of the type recom-
mended for the compressor i n the vehi cl e.
(5) Fi t the femal e fi tti ng to the mal e fi tti ng and
push together unti l the garter spri ng snaps over the
fl ared end of the femal e fi tti ng.
(6) Ensure the coupl er i s ful l y engaged by pul l i ng
back on the l i nes on ei ther si de of the coupl er.
(7) I nstal l the secondary cl i p on the coupl er.
COMPRESSOR
GASOLINE ENGINE
The compressor may be removed and reposi ti oned
wi thout di sconnecti ng the refri gerant l i nes or di s-
chargi ng the refri gerant system on model s equi pped
wi th a gasol i ne engi ne. Di schargi ng i s not necessary
i f servi ci ng the compressor cl utch or cl utch coi l , the
engi ne, the cyl i nder head, or the generator.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Loosen and remove the serpenti ne dri ve bel t.
Refer to Group 7 - Cool i ng System for the procedures.
Refrigerant Oil Capacities
Component ml oz
A/C System 230 7.75
Accumulator 120 4
Condenser 30 1
Evaporator 60 2
Compressor drain and measure the oil from the
old compressor - see text.
Fig. 20 Spring Lock Coupler Disconnect
ZG HEATING AND AIR CONDITIONING 24 - 31
(3) Unpl ug the compressor cl utch coi l wi re harness
connector.
(4) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(5) Remove the refri gerant l i nes from the compres-
sor. I nstal l pl ugs i n, or tape over al l of the open
refri gerant fi tti ngs.
(6) Remove the bol ts that secure the compressor to
the mounti ng bracket, and l i ft the compressor from
the mounti ng bracket.
INSTALLATION
NOTE: If a replacement compressor is being
installed, be certain to check the oil level. See
Refrigerant Oil Level in this group.
(1) I f the compressor mounti ng bracket was
removed, i nstal l the bracket to the engi ne. Ti ghten
the mounti ng bol ts to 27 Nm (20 ft. l bs.).
(2) I nstal l the compressor on the mounti ng
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.).
(3) Remove the tape or pl ugs from al l of the refri g-
erant fi tti ngs, and i nstal l the refri gerant l i nes on the
compressor.
(4) I nstal l the serpenti ne dri ve bel t. Refer to
Group 7 - Cool i ng System for the procedures.
(5) Pl ug i n the compressor cl utch coi l wi re harness
connector.
(6) Connect the battery negati ve cabl e.
(7) Evacuate and charge the refri gerant system as
descri bed i n thi s group.
DIESEL ENGINE
The compressor and cl utch may onl y be removed as
a uni t on model s equi pped wi th a di esel engi ne.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(3) Unpl ug the compressor cl utch coi l wi re harness
connector.
(4) Remove the refri gerant l i ne bracket from the
engi ne val ve cover.
(5) Remove the refri gerant l i nes from the compres-
sor. I nstal l pl ugs i n, or tape over al l of the open
refri gerant fi tti ngs.
(6) Rai se and support the vehi cl e.
(7) Remove the bol ts that secure the compressor
cl utch dri ve spool to the power steeri ng pump dri ve
fl ange.
(8) Remove the four compressor mounti ng bol ts
and spacers, and remove the compressor and cl utch
uni t from the engi ne bl ock.
(9) Remove the compressor cl utch and dri ve spool
from the compressor as descri bed i n thi s group.
INSTALLATION
NOTE: If a replacement compressor is being
installed, be certain to check the oil level. See
Refrigerant Oil Level in this group.
(1) I nstal l the compressor cl utch and dri ve spool
on the compressor as descri bed i n thi s group.
(2) I nstal l the compressor on the engi ne bl ock
usi ng the four mounti ng bol ts and spacers. Ti ghten
the bol ts to 24 Nm (18 ft. l bs.).
(3) I nstal l the bol ts that secure the compressor
cl utch dri ve spool to the power steeri ng pump dri ve
fl ange. Ti ghten the bol ts to 16 Nm (12 ft. l bs.).
(4) Lower the vehi cl e.
(5) Remove the tape or pl ugs from al l of the refri g-
erant fi tti ngs, and i nstal l the refri gerant l i nes on the
compressor.
(6) I nstal l the refri gerant l i ne bracket on the
engi ne val ve cover. Ti ghten the bol t to 5.6 Nm (50
i n. l bs.).
(7) Pl ug i n the compressor cl utch coi l wi re harness
connector.
(8) Connect the battery negati ve cabl e.
(9) Evacuate and charge the refri gerant system as
descri bed i n thi s group.
COMPRESSOR CLUTCH
GASOLINE ENGINE
The refri gerant system can remai n ful l y-charged
duri ng compressor cl utch, pul l ey, or coi l repl acement
on gasol i ne engi ne model s. The compressor cl utch
can be servi ced i n the vehi cl e.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the compressor shaft bol t (Fi g. 21). A
band-type oi l fi l ter wrench may be used to ai d i n
securi ng the cl utch duri ng bol t removal .
(3) Tap the cl utch pl ate wi th a pl asti c mal l et to
rel ease i t from the spl i nes on the compressor shaft.
Remove cl utch pl ate and shi m(s) from the compressor
shaft (Fi g. 22).
24 - 32 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
CAUTION: Do not pry between the clutch plate
assembly and the pulley to remove the front plate.
This may damage the front plate assembly.
(4) Remove the pul l ey retai ni ng snap ri ng wi th
snap ri ng pl i ers (Speci al Tool C-4574) and sl i de the
pul l ey assembl y off of the compressor (Fi g. 23).
(5) Unpl ug the cl utch coi l wi re harness connector.
Remove the screw and retai ner from the cl utch coi l
wi re harness on the compressor front housi ng.
(6) Remove the snap ri ng from the compressor hub
and remove the cl utch fi el d coi l (Fi g. 24). Sl i de the
cl utch fi el d coi l off of the compressor hub.
INSPECTION
Exami ne the fri cti on surfaces of the cl utch pul l ey
and the front pl ate for wear. The pul l ey and front
pl ate shoul d be repl aced i f there i s excessi ve wear or
scori ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for oi l . Remove the
fel t from the front cover. I f the fel t i s saturated wi th
oi l , the shaft seal i s l eaki ng and the compressor must
be repl aced.
Check the cl utch pul l ey beari ng for roughness or
excessi ve l eakage of grease. Repl ace the beari ng, i f
requi red.
INSTALLATION
(1) Al i gn the dowel pi n on the back of the cl utch
fi el d coi l wi th the hol e i n the compressor front hous-
i ng and press the fi el d coi l i nto pl ace.
Fig. 21 Compressor Shaft Bolt
COMPRESSOR CLUTCH PLATE COMPRESSOR SHAFT BOLT
Fig. 22 Clutch Plate and Shim
COMPRESSOR SHAFT CLUTCH PLATE CLUTCH PLATE SHIM
Fig. 23 Pulley Snap Ring Remove/Install
SNAP RING
Fig. 24 Clutch Coil Snap Ring Remove/Install
SNAP RING PLIERS CLUTCH COIL SNAP RING COMPRESSOR
ZG HEATING AND AIR CONDITIONING 24 - 33
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l the cl utch coi l wi re harness retai ni ng
cl i p on the compressor front housi ng and ti ghten the
retai ni ng screw. Pl ug i n the cl utch coi l wi re harness
connector.
(3) I nstal l the cl utch fi el d coi l and snap ri ng wi th
snap ri ng pl i ers (Speci al Tool C-4574). The bevel si de
of the snap ri ng must be faci ng outward. Al so, both
eyel ets of the snap ri ng must be to the ri ght or l eft of
the pi n on the compressor. Press the snap ri ng to
make sure i t i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(4) I nstal l the pul l ey assembl y onto the compres-
sor. I f necessary, pl ace a bl ock of wood on the fri cti on
surface and tap gentl y wi th a hammer (Fi g. 25).
CAUTION: Do not mar the pulley friction surface.
(5) I nstal l the pul l ey assembl y retai ni ng snap ri ng
(bevel si de outward) wi th snap ri ng pl i ers (Speci al
Tool C-4574). Press the snap ri ng to make sure i t i s
properl y seated i n the groove.
(6) I f the ori gi nal front pl ate assembl y and pul l ey
assembl y are to be reused, the ol d shi m(s) can be
used. I f not, pl ace a stack of shi m(s) equal to the ol d
shi m(s) on the shaft agai nst the shoul der.
(7) I nstal l the front pl ate assembl y onto the shaft.
(8) Wi th the front pl ate assembl y ti ght agai nst the
shi m(s), measure the ai r gap between the front pl ate
and the pul l ey face wi th feel er gauges. The ai r gap
shoul d be 0.35 to 0.65 mm (0.014 to 0.026 i n.). I f the
proper ai r gap i s not obtai ned, add or subtract shi ms
as needed unti l the desi red ai r gap i s obtai ned.
(9) I nstal l the compressor shaft bol t. Ti ghten the
bol t to 13 Nm (115 i n. l bs.).
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is still correct. Spin the
pulley before performing a final check of the air
gap.
(10) Connect the battery negati ve cabl e.
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the heater-A/C control to the A/C
(Reci rc) mode, the bl ower motor swi tch i n the hi ghest
speed posi ti on, and the engi ne speed at 1500 to 2000
rpm. Thi s procedure (burni shi ng) wi l l seat the oppos-
i ng fri cti on surfaces and provi de a hi gher compressor
cl utch torque capabi l i ty.
DIESEL ENGINE
The refri gerant must be recovered from the refri g-
erant system duri ng compressor cl utch, dri ve, or coi l
repl acement on di esel engi ne model s. The compressor
cl utch cannot be servi ced i n the vehi cl e.
REMOVAL
(1) Remove the compressor and cl utch from the
vehi cl e as descri bed i n thi s group.
(2) Mount the compressor i n a vi se and remove the
bol ts that secure the dri ve spool to the dri ve pl ate.
(3) Remove the compressor dri ve pl ate wi th a
spanner wrench (Speci al Tool 3281). Turn the dri ve
pl ate countercl ockwi se to remove (Fi g. 26).
Fig. 25 Pulley Assembly Install
PULLEY ASSEMBLY WOOD BLOCK
Fig. 26 Drive Plate Remove
HOLDING TOOL SPECIAL TOOL 3281 DRIVE PLATE
24 - 34 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
(4) I nsert the two pi ns of the spanner wrench i nto
two hol es of the cl utch pl ate. Hol d the cl utch pl ate
stati onary and remove the bol t that secures the
cl utch pl ate to the compressor shaft.
(5) Remove the cl utch pl ate (Fi g. 27).
(6) Remove the external snap ri ng from the front
compressor housi ng hub wi th snap ri ng pl i ers and
remove the cl utch rotor and beari ng assembl y (Fi g.
28).
(7) Remove the screw and retai ner from the cl utch
coi l wi re harness on the compressor front housi ng.
(8) Remove the snap ri ng from the compressor hub
and remove the cl utch fi el d coi l (Fi g. 29). Sl i de the
cl utch fi el d coi l off of the compressor hub.
INSPECTION
Exami ne the fri cti on surfaces of the cl utch dri ve
pl ate and the cl utch pl ate for wear. The dri ve pl ate
and cl utch pl ate shoul d be repl aced i f there i s exces-
si ve wear or scori ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for oi l . Remove the
fel t from the front cover. I f the fel t i s saturated wi th
oi l , the shaft seal i s l eaki ng and the compressor must
be repl aced.
Check the cl utch dri ve pl ate beari ng for roughness
or excessi ve l eakage of grease. Repl ace the beari ng, i f
requi red.
INSTALLATION
(1) Al i gn the dowel pi n on the back of the cl utch
fi el d coi l wi th the hol e i n the compressor front hous-
i ng and press the fi el d coi l i nto pl ace.
(2) I nstal l the cl utch coi l wi re l ead retai ni ng cl i p
on the compressor front housi ng and ti ghten the
retai ni ng screw.
(3) I nstal l the cl utch fi el d coi l and snap ri ng wi th
snap ri ng pl i ers. The bevel si de of the snap ri ng must
be faci ng outward. Press the snap ri ng to make sure
i t i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(4) Check that the ori gi nal cl utch spacer shi ms are
i n pl ace on the compressor shaft and i nstal l the
cl utch pl ate. Repl ace the shaft bol t and ti ghten to
14.4 Nm (10.5 ft. l bs.).
NOTE: The clutch air gap is determined by the
spacer shims. When installing the original or a new
clutch assembly, try the original shims first. When
installing a new clutch onto a compressor that pre-
viously did not have a clutch, use 0.040, 0.020, and
0.005 in. shims from the clutch accessory sack.
(5) Check the ai r gap wi th a feel er gauge (Fi g. 30).
I f the ai r gap does not meet the speci fi cati on add or
Fig. 27 Clutch Plate Remove/Install
CLUTCH PLATE ROTOR BEARING ASSEMBLY
Fig. 28 External Snap Ring Remove/Install
SNAP RING ROTOR BEARING ASSEMBLY
Fig. 29 Clutch Coil Snap Ring Remove/Install
SNAP RING COIL
ZG HEATING AND AIR CONDITIONING 24 - 35
REMOVAL AND INSTALLATION (Continued)
subtract shi ms as requi red. The speci fi cati on i s 0.41
to 0.79 mm (0.016 to 0.031 i nch). I f the ai r gap i s not
consi stent around the ci rcumference, l i ghtl y pry up
at the poi nts of mi ni mum vari ati on. Li ghtl y tap down
at the poi nts of maxi mum vari ati on.
(6) I nstal l the dri ve pl ate onto the cl utch and
ti ghten to 98 Nm (72 ft. l bs.).
(7) I nstal l the dri ve spool onto the dri ve pl ate.
Ti ghten the dri ve spool bol ts to 16 Nm (12 ft. l bs.).
(8) Reverse the remai ni ng removal procedures to
compl ete the i nstal l ati on.
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the heater-A/C control to the A/C
(Reci rc) mode, the bl ower motor swi tch i n the hi ghest
speed posi ti on, and the engi ne speed at 1500 to 2000
rpm. Thi s procedure (burni shi ng) wi l l seat the oppos-
i ng fri cti on surfaces and provi de a hi gher compressor
cl utch torque capabi l i ty.
COMPRESSOR CLUTCH RELAY
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 31).
(3) Refer to the l abel on the PDC for compressor
cl utch rel ay i denti fi cati on and l ocati on.
(4) Unpl ug the compressor cl utch rel ay from the PDC.
(5) I nstal l the compressor cl utch rel ay by al i gni ng
the rel ay termi nal s wi th the cavi ti es i n the PDC and
pushi ng the rel ay fi rml y i nto pl ace.
(6) I nstal l the PDC cover.
(7) Connect the battery negati ve cabl e.
(8) Test the rel ay operati on.
HIGH PRESSURE CUT-OFF SWITCH
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the wi re harness connector from the
swi tch (Fi g. 32).
(3) Unscrew the swi tch from the di scharge l i ne fi t-
ti ng.
INSTALLATION
(1) I nstal l and ti ghten the swi tch.
(2) Pl ug the wi re harness connector i nto the
swi tch.
(3) Connect the battery negati ve cabl e.
Fig. 30 Check Air Gap
FEELER GAUGE
Fig. 31 Power Distribution Center
NEGATIVE CABLE
POWER DISTRIBUTION CEN- TER
Fig. 32 High Pressure Cut-Off Switch - Typical
MANIFOLD HIGH PRESSURE SERVICE PORT HIGH PRESSURE CUTOUT SWITCH DISCHARGELINE SUCTION LINE
24 - 36 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
HIGH PRESSURE RELIEF VALVE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve cabl e.
(2) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(3) Turn the rel i ef val ve countercl ockwi se to
remove i t from the compressor mani fol d (Fi g. 33).
(4) Ei ther i nstal l a pl ug i n, or tape over the open
fi tti ng on the compressor mani fol d.
INSTALLATION
(1) Remove the pl ug or tape from the compressor
mani fol d fi tti ng.
(2) I nstal l the hi gh pressure rel i ef val ve i n the
compressor mani fol d.
(3) Evacuate and charge the refri gerant system as
descri bed i n thi s group.
(4) Connect the battery negati ve cabl e.
CONDENSER
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
CAUTION: When removing the condenser note the
locations of all of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. They must be installed in
their original locations to prevent engine overheat-
ing (Fig. 34).
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(3) Di sconnect the refri gerant l i nes from the con-
denser. I nstal l pl ugs i n, or tape over al l of the open
refri gerant fi tti ngs.
(4) Remove the radi ator gri l l e panel . Refer to
Group 23 - Body for the procedures.
(5) Remove the upper bol ts from the two radi ator
braces (Fi g. 35).
(6) Remove the two nuts that secure the radi ator
to the crossmember (Fi g. 36).
(7) Reach through the gri l l e openi ng and remove
the bol t that secures the l ower hood l atch support to
the l ower front crossmember.
(8) The radi ator upper crossmember can be
adjusted l eft or ri ght through the use of i ts sl otted
mounti ng hol es. Before removal , mark the ori gi nal
posi ti on of the crossmember.
(9) Remove the remai ni ng bol ts that secure the
radi ator upper crossmember to the body. Do not
remove the hood l atch or hood l atch cabl e from the
crossmember. Li ft the crossmember strai ght up and
l ay i t to the si de.
(10) Remove the four bol ts that secure the l ower
condenser.
(11) Remove the two bol ts that secure the upper
condenser.
(12) Careful l y remove the condenser from the vehi -
cl e.
INSTALLATION
(1) Careful l y posi ti on the condenser i n the vehi cl e.
(2) I nstal l and ti ghten the two bol ts that secure
the upper condenser.
(3) I nstal l and ti ghten the four bol ts that secure
the l ower condenser.
(4) Al i gn the radi ator upper crossmember wi th the
scri be marks. I nstal l and ti ghten the bol ts that
secure the radi ator upper crossmember to the body.
(5) I nstal l and ti ghten the nuts that secure the
radi ator to the upper crossmember.
(6) Reach through the gri l l e openi ng to i nstal l and
ti ghten the bol t that secures the l ower hood l atch
support to the l ower front crossmember.
(7) I nstal l and ti ghten the two bol ts that secure
the radi ator braces to the upper radi ator crossmem-
ber.
Fig. 33 High Pressure Relief Valve - Typical
HIGH PRESSURE RELIEF VALVE HIGH PRESSURE SER- VICE PORT COMPRESSOR MANIFOLD 5.2L 4.0L VIEWS FROM TOP FWD
ZG HEATING AND AIR CONDITIONING 24 - 37
REMOVAL AND INSTALLATION (Continued)
(8) I nstal l the gri l l e panel .
(9) Remove the pl ugs or tape from the open refri g-
erant l i ne fi tti ngs and connect the refri gerant l i nes to
the condenser.
(10) Evacuate the refri gerant system as descri bed
i n thi s group.
(11) Charge the refri gerant system as descri bed i n
thi s group.
(12) Connect the battery negati ve cabl e.
NOTE: If the condenser is replaced, add 30 ml (1
oz.) of refrigerant oil to the refrigerant system.
Fig. 34 Air Seals
SEALS (BETWEEN A/C CON- DENSER AND RADIATOR) RADIATOR TO BODY SEAL (RIGHT) UPPER SEALS (BETWEEN RADI- ATOR AND UPPER CROSSMEM- BER) RADIATOR ALIGNMENT DOWELS (2) RADIATOR TO BODY SEAL (LEFT) LOWER SEAL A/C CONDENSER
Fig. 35 Condenser Mounting
CONDENSER BOLT FAN SHROUD MOUNTING NUTS UPPER BRACE BOLTS CONDENSER BOLT ALIGNMENT DOWELS LOWER BRACKETBOLT HOOD LATCH BRACKET
Fig. 36 Radiator Upper Crossmember - Typical
CONDENSER-TO-RA- DIATOR MOUNTING BRACKETS (2) UPPER CROSS- MEMBER FAN SHROUD ALIGNMENT TABS RADIATOR ALIGNMENT DOWELS (2) RUBBER ISOLATORS (2) RUBBER GROMMETS (2) LOWER CROSSMEMBER CONDENSER
24 - 38 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
FIXED ORIFICE TUBE
The fi xed ori fi ce tube i s l ocated i n the l i qui d l i ne
near the condenser. The ori fi ce has fi l ter screens on
the i nl et and outl et ends of the tube body. I f the fi xed
ori fi ce tube i s faul ty or pl ugged, the l i qui d l i ne must
be repl aced.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(3) Di sconnect the refri gerant l i ne coupl ers at the
condenser outl et l i ne and the evaporator i nl et l i ne.
I nstal l pl ugs i n, or tape over al l of the open refri ger-
ant fi tti ngs.
(4) Remove the l i qui d l i ne from the vehi cl e.
INSTALLATION
(1) Remove the pl ugs or tape from the refri gerant
l i ne fi tti ngs. Connect the l i qui d l i ne at the evaporator
i nl et l i ne and the condenser outl et l i ne.
(2) Evacuate and charge the refri gerant system as
descri bed i n thi s group.
(3) Connect the battery negati ve cabl e.
ACCUMULATOR
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(3) Di sconnect the refri gerant l i nes from the accu-
mul ator. I nstal l pl ugs i n, or tape over al l of the open
refri gerant fi tti ngs.
(4) Unpl ug the wi re harness connector from the
l ow pressure cycl i ng cl utch swi tch (Fi g. 37).
(5) Loosen the screw that secures the accumul ator
band to the support bracket.
(6) Remove the accumul ator.
INSTALLATION
(1) I nstal l the accumul ator band screw i n the sup-
port bracket.
(2) Ti ghten the band screw i n the support bracket.
(3) Pl ug the wi re harness connector i nto the l ow
pressure cycl i ng cl utch swi tch.
(4) Remove the pl ugs or tape from the refri gerant
l i ne fi tti ngs. Connect the refri gerant l i nes to the
accumul ator.
(5) Evacuate and charge the refri gerant system as
descri bed i n thi s group.
(6) Connect the battery negati ve cabl e.
NOTE: If the accumulator is replaced, add 120 ml (4
oz.) of refrigerant oil to the refrigerant system.
LOW PRESSURE CYCLING CLUTCH SWITCH
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the wi re harness connector from the
swi tch.
(3) Unscrew the swi tch from the fi tti ng on the
accumul ator.
(4) Reverse the removal procedures to i nstal l .
AMBIENT TEMPERATURE SENSOR
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the radi ator gri l l e uni t. Refer to Group
23 - Body for the procedures.
(3) Locate the temperature sensor, on the radi ator
support behi nd the gri l l e (Fi g. 38).
(4) Unpl ug the temperature sensor wi re harness
connector.
(5) Remove the temperature sensor mounti ng bol t
and remove the sensor.
(6) Reverse the removal procedures to i nstal l .
Fig. 37 Accumulator and Bracket
CLUTCH CYCLING PRES- SURE SWITCH ACCUMULATOR SUPPORT BRACKET
ZG HEATING AND AIR CONDITIONING 24 - 39
REMOVAL AND INSTALLATION (Continued)
VACUUM CHECK VALVE
(1) Unpl ug the vacuum suppl y l i ne at the i ntake
mani fol d.
(2) Note the ori entati on of the check val ve i n the
vacuum l i ne for correct i nstal l ati on.
(3) Unpl ug the val ve from the vacuum suppl y l i ne
fi tti ngs.
(4) Reverse the removal procedures to i nstal l .
VACUUM RESERVOIR
(1) Remove the battery from the battery tray.
Refer to Group 8A - Battery for the procedures.
(2) Remove the fi ve screws that secure the battery
tray to the vehi cl e.
(3) Pul l up the battery tray far enough to unpl ug
the vacuum harness connector from the reservoi r
(Fi g. 39).
(4) Remove the battery tray and vacuum reservoi r
from the vehi cl e as a uni t.
(5) Remove the two screws that secure the vacuum
reservoi r to the battery tray.
(6) Remove the vacuum reservoi r from the battery
tray.
(7) Reverse the removal procedures to i nstal l .
HEATER-A/C CONTROL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Usi ng a tri m sti ck or other sui tabl e wi de fl at-
bl aded tool , pry gentl y around the edges of the
i nboard swi tch pod bezel and remove the bezel .
(3) Remove the three screws that secure the heat-
er-A/C control to the i nstrument panel (Fi g. 40).
(4) Pul l the heater-A/C control out from the i nstru-
ment panel far enough to access the connectors on
the back of the control .
(5) Unpl ug the wi re and/or vacuum harness con-
nectors from the back of the heater-A/C control (Fi g.
41).
Fig. 38 Temperature Sensor Remove/Install
AMBIENT AIR TEMP SEN- SOR CONNECTOR SENSOR MOUNT- ING BOLT LOWER FRONT CROSSMEMBER RADIATOR SUP- PORT FWD
Fig. 39 Vacuum Reservoir Remove/Install
BATTERY TRAY VACUUM HOSE VACUUM RESERVOIR RESERVOIR ATTACHING SCREW (2) FWD
Fig. 40 Heater-A/C Control Remove/Install
MOUNTING SCREWS
24 - 40 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
(6) Remove the heater-A/C control from the i nstru-
ment panel .
INSTALLATION
(1) Connect the vacuum and wi re harness connec-
tors to the heater-A/C control .
(2) I nstal l the heater-A/C control to the i nstrument
panel and secure wi th three screws.
(3) I nstal l the i nboard swi tch pod bezel .
(4) Connect the battery negati ve cabl e.
SOLAR SENSOR
Thi s sensor i s used onl y on model s wi th the
opti onal Automati c Temperature Control (ATC) sys-
tem.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Usi ng a tri m sti ck or other sui tabl e wi de fl at-
bl aded tool , pry gentl y al ong the edge of the i nstru-
ment panel cowl top tri m panel to rel ease the snap
cl i p retai ners (Fi g. 42).
(3) Li ft the cowl top tri m panel far enough to
reach underneath i t to access the sol ar sensor, whi ch
i s l ocated between the passenger si de and center
defroster outl ets.
(4) Use a twi sti ng moti on to remove the sol ar sen-
sor from the cowl top tri m panel (Fi g. 43).
(5) Pul l the sensor out far enough to access the
wi re harness connector and unpl ug i t from the
i nstrument panel wi re harness.
INSTALLATION
(1) Pl ug i n the sol ar sensor wi re harness connec-
tor.
(2) I nstal l the sol ar sensor i nto the cowl top tri m
panel .
(3) Press the cowl top tri m panel down unti l the
snap cl i p retai ners engage i n the top of the i nstru-
ment panel .
(4) Connect the battery negati ve cabl e.
IN-VEHICLE TEMPERATURE SENSOR
Thi s sensor i s used onl y on model s wi th the
opti onal Automati c Temperature Control (ATC) sys-
tem.
Fig. 41 Heater-A/C Control Connectors - Typical
HEATER-A/C CONTROL PANEL VACUUM CON- NECTOR
Fig. 42 Cowl Top Trim Remove/Install
COWL TOP TRIM PANEL INSTRUMENT PANEL
Fig. 43 Solar Sensor
DEFROST GRILLE SOLAR SENSOR SOLAR SENSOR CONNECTOR
ZG HEATING AND AIR CONDITIONING 24 - 41
REMOVAL AND INSTALLATION (Continued)
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the gl ove box modul e. Refer to Group
8E - I nstrument Panel Systems for the procedures.
(3) Di sconnect the aspi rator hose at the i n-l i ne
spl i ce connector near the passenger si de of the fl oor
pan transmi ssi on tunnel and under the i nstrument
panel (Fi g. 44).
(4) Reach behi nd the sensor and unpl ug the wi re
harness connector.
(5) Remove the two screws that secure the sensor
assembl y to the i nstrument panel .
(6) Remove the sensor assembl y from the i nstru-
ment panel .
INSTALLATION
(1) I nsert the i n-vehi cl e temperature sensor i nto
the i nstrument panel .
(2) I nstal l two screws to secure the sensor to the
i nstrument panel .
(3) Pl ug i n the sensor wi re harness connector.
(4) Connect the aspi rator hose to the i n-l i ne spl i ce
connector.
(5) I nstal l the gl ove box modul e. Refer to Group
8E - I nstrument Panel Systems for the procedures.
(6) Connect the battery negati ve cabl e.
BLOWER MOTOR
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Di sconnect the bl ower motor cool i ng tube (Fi g.
45).
(3) Remove the bl ower motor wi re harness from
the retai ner. Unpl ug the wi re harness connector from
the bl ower motor.
(4) Remove the screws that secure the bl ower
motor and wheel assembl y to the heater-A/C housi ng.
(5) Remove the bl ower motor and wheel from the
heater-A/C housi ng.
(6) Remove the bl ower motor wheel retai ner cl i p
and remove the wheel from the bl ower motor shaft
(Fi g. 46).
INSTALLATION
(1) Press the bl ower motor wheel hub onto the
bl ower motor shaft. Be sure the fl at on the shaft
l i nes up wi th the fl at i nsi de the hub.
(2) I nstal l the retai ner cl i p. The ears of the
retai ner cl i p must be over the fl at surface on the
motor shaft.
(3) Be certai n that the bl ower motor seal i s
i nstal l ed on the bl ower motor housi ng (Fi g. 47).
(4) I nstal l the bl ower motor i n the heater-A/C
housi ng.
(5) I nstal l and ti ghten the screws that secure the
bl ower motor to the heater-A/C housi ng.
Fig. 44 In-Vehicle Temperature Sensor
MOUNTING SCREWS IN-CAR TEMPERATURE SEN- SOR ASPIRATOR HOSE
Fig. 45 Blower Motor
BLOWER MOTOR HOUS- ING COOLING TUBE ELECTRICAL CON- NECTOR
24 - 42 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
(6) Pl ug the wi re harness connector i nto the
bl ower motor and i nstal l the wi re harness i nto the
retai ner.
(7) Connect the bl ower motor cool i ng tube.
(8) Connect the battery negati ve cabl e.
BLOWER MOTOR RESISTOR AND POWER
MODULE
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the bl ower motor resi stor/power modul e
wi re harness connector.
(3) Remove the screws that secure the resi stor/
power modul e to the heater-A/C housi ng.
(4) Remove the bl ower motor resi stor/power mod-
ul e (Fi g. 48).
INSTALLATION
(1) I nstal l the bl ower motor resi stor/power modul e
to the heater-A/C housi ng. I nstal l and ti ghten the
screws.
(2) Pl ug i n the resi stor/modul e wi re harness con-
nector.
(3) Connect the battery negati ve cabl e.
HIGH SPEED BLOWER MOTOR RELAY
Thi s rel ay i s used onl y on model s equi pped wi th
the opti onal Automati c Temperature Control (ATC)
system.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Locate the bl ower motor rel ay near the out-
board end of the heater-A/C housi ng under the pas-
senger si de of the i nstrument panel (Fi g. 49).
Fig. 46 Blower Motor Wheel
BLOWER MOTOR WHEEL RETAINER CLIP
Fig. 47 Blower Motor Seal
BLOWER MOTOR SEAL
Fig. 48 Blower Motor Resistor or Power
ModuleRemove/Install
BLOWERMOTOR BLOWER MOTOR RESISTOR
ZG HEATING AND AIR CONDITIONING 24 - 43
REMOVAL AND INSTALLATION (Continued)
(3) Uncl i p the bl ower motor rel ay wi re harness
connector from the si de of the heater-A/C housi ng.
(4) Unpl ug the bl ower motor rel ay from the con-
nector.
INSTALLATION
(1) Al i gn the bl ower motor rel ay termi nal s wi th
the cavi ti es i n the bl ower motor rel ay wi re harness
connector.
(2) Push the rel ay fi rml y i nto the connector.
(3) Cl i p the bl ower motor rel ay and connector back
onto the heater-A/C housi ng.
(4) Connect the battery negati ve cabl e.
TEMPERATURE/BLEND AIR DOOR MOTOR
The temperature/bl end ai r door motor i s l ocated
under the i nstrument panel and can be removed from
the passenger compartment.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the wi re harness connector from the
motor (Fi g. 50).
(3) Remove the screws that secure the motor to the
heater-A/C housi ng.
(4) Remove the temperature/bl end ai r door motor.
INSTALLATION
(1) Posi ti on the motor over the door connecti on.
(2) I nstal l and ti ghten the screws that secure the
motor to the heater-A/C housi ng.
(3) Pl ug i n the wi re harness connector to the
motor.
(4) Connect the battery negati ve cabl e.
DUCTS AND OUTLETS
DEFROSTER DUCT
(1) Remove the i nstrument panel from the vehi cl e
as descri bed i n Group 8E - I nstrument Panel Sys-
tems.
(2) Remove the three screws that secure the
defroster duct to the i nstrument panel armature.
(3) Remove the defroster duct.
(4) Reverse the removal procedures to i nstal l .
DEMISTER DUCTS
(1) Remove the defroster duct as descri bed i n thi s
group.
(2) Remove the four screws that secure the demi s-
ter ducts to the i nstrument panel armature.
(3) Remove the demi ster ducts.
(4) Reverse the removal procedures to i nstal l .
PANEL DUCTS
(1) Remove the demi ster ducts as descri bed i n thi s
group.
(2) Remove the four screws that secure the panel
ducts to the i nstrument panel armature.
(3) Remove the panel ducts.
(4) Reverse the removal procedures to i nstal l .
FLOOR DUCTS
(1) Remove the center fl oor consol e as descri bed i n
Group 23 - Body.
(2) Remove the ri ght front seat as descri bed i n
Group 23 - Body.
(3) Remove the ri ght si de front door openi ng tri m
as descri bed i n Group 23 - Body.
(4) Rol l back the fl oor carpeti ng.
Fig. 49 High Speed Blower Motor Relay
RECIRCULATING DOOR SHAFT RETAINER ROD CLIP ACTUATOR 16WAY CONNEC- TOR BLOWER MOTOR ELEC- TRICAL CON- NECTOR BLOWER MOTOR HIGH SPEED BLOWER MOTOR RELAY
Fig. 50 Temperature/Blend Air Door Motor
TEMPERATURE BLEND AIR DOOR MOTOR ELECTRICAL CONNECTOR
24 - 44 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
(5) Remove the nut that secures the fl oor duct to
the stud on the fl oor pan transmi ssi on tunnel (Fi g.
51).
(6) Di sconnect the fl oor duct from the center adap-
tor duct.
(7) Remove the fl oor duct from the vehi cl e.
(8) Reverse the removal procedures to i nstal l .
DEMISTER OUTLETS
(1) Usi ng a tri m sti ck or other sui tabl e wi de fl at-
bl aded tool , pry the edge of the outl et away from the
i nstrument panel top pad.
(2) To i nstal l , push the outl et fi rml y i nto the hol e
i n the i nstrument panel top pad.
PANEL OUTLETS
The dri ver si de and center panel outl ets are onl y
servi ced as part of the i nstrument cl uster bezel uni t.
The passenger si de panel outl ets are avai l abl e for
servi ce.
(1) Remove the i nstrument panel top pad as
descri bed i n Group 8E - I nstrument Panel Systems.
(2) Remove the two screws that secure each outl et
to the top pad.
(3) Remove the outl et from the top pad.
(4) Reverse the removal procedures to i nstal l .
PANEL/DEFROST DOOR
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument panel as descri bed i n
Group 8E - I nstrument Panel Systems.
(3) Di sconnect the panel /defrost door actuati ng rod
(Fi g. 52) or (Fi g. 53).
(4) Pry the panel /defrost door pi vot shaft retai ner
from the pi vot shaft.
(5) Remove the door through the top openi ng of
the heater-A/C housi ng.
Fig. 51 Floor Duct Remove/Install
CENTER ADAPTOR HEAT DUCT FWD REAR FLOOR HEAT DUCT
Fig. 52 Panel/Defrost Door - Manual
VACUUM LINE PANEL/DEFROST ACTUATOR SHAFT RETAINER
Fig. 53 Panel/Defrost Door - ATC
SHAFT RETAINER ACTUATINGROD PANEL/DEFROST DOOR
ZG HEATING AND AIR CONDITIONING 24 - 45
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l the panel /defrost door through the top
openi ng and pl ace i nto posi ti on i n the heater-A/C
housi ng.
(2) Press the door pi vot shaft retai ner onto the
pi vot shaft.
(3) Connect the actuati ng rod and rod cl i p to the
shaft retai ner.
(4) I nstal l the i nstrument panel as descri bed i n
Group 8E - I nstrument Panel Systems.
(5) Connect the battery negati ve cabl e.
RECIRCULATING AIR DOOR ACTUATOR
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the i nstrument panel as descri bed i n
Group 8E - I nstrument Panel Systems.
(3) Unpl ug the actuator vacuum harness connector
(Fi g. 54) or wi re harness connector (Fi g. 55), as
equi pped.
(4) Di sconnect the actuati ng rod cl i p.
(5) Remove the screws that secure the actuator to
the heater-A/C housi ng.
(6) Remove the actuator from the heater-A/C hous-
i ng.
INSTALLATION
(1) Posi ti on the actuator on the heater-A/C hous-
i ng.
(2) I nstal l and ti ghten the screws that secure the
actuator to the housi ng.
(3) Connect the actuati ng rod and cl i p to the door
l ever.
(4) Pl ug i n the vacuum harness connector or the
wi re harness connector to the actuator, as equi pped.
(5) I nstal l the i nstrument panel as descri bed i n
Group 8E - I nstrument Panel Systems.
(6) Connect the battery negati ve cabl e.
HEATER-A/C HOUSING
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(3) Di sconnect the refri gerant l i nes from the evap-
orator tubes (Fi g. 56). I nstal l pl ugs i n, or tape over
al l of the open refri gerant fi tti ngs.
(4) Drai n the cool i ng system. Refer to Group 7 -
Cool i ng System for the procedures.
(5) Di sconnect the heater hoses from the heater
core tubes.
(6) Remove the cool ant reserve/overfl ow bottl e.
(7) Remove the Powertrai n Control Modul e (PCM)
and set i t asi de. Do not unpl ug the PCM wi re har-
ness connectors.
(8) Remove the heater-A/C housi ng mounti ng nuts
from the studs on the engi ne compartment si de of
the dash panel .
(9) Remove the i nstrument panel . Refer to Group
8E - I nstrument Panel Systems for the procedures.
(10) Di sconnect the rear fl oor heat duct from the
center adaptor (Fi g. 57).
Fig. 54 Recirculating Air Door Actuator -Manual
DOOR SHAFT RETAINER RECIRCULATING AIR DOOR ROD CLIP BLOWER MOTOR ELECTRICAL CONNECTOR ACTUATOR BLOWER MOTOR VACUUM LINE
Fig. 55 Recirculating Air Door Actuator -ATC
RECIRCULATING DOOR SHAFT RETAINER ROD CLIP ACTUATOR 16 WAY CONNECTOR BLOWER MOTOR ELEC- TRICAL CON- NECTOR BLOWER MOTOR ELECTRICAL CON- NECTOR
24 - 46 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
(11) Unpl ug the heater-A/C housi ng wi re harness
connectors.
(12) Remove the heater-A/C housi ng mounti ng
nuts from the studs on the passenger compartment
si de of the dash panel (Fi g. 58).
(13) Remove the heater-A/C housi ng from the vehi -
cl e.
INSTALLATION
(1) Posi ti on the heater-A/C housi ng to the dash
panel . Be sure the drai n tube i s posi ti oned i n the
dash panel drai n hol e.
(2) I nstal l the mounti ng nuts to the studs on the
passenger compartment si de of the dash panel .
Ti ghten the nuts to 4.5 Nm (40 i n. l bs.).
(3) I nstal l the mounti ng nuts to the studs on the
engi ne compartment si de of the dash panel . Ti ghten
the nuts to 7 Nm (60 i n. l bs.).
(4) Connect the heater hoses to the heater core
tubes.
(5) Unpl ug or remove the tape from the refri gerant
fi tti ngs, and connect the refri gerant l i nes to the evap-
orator tubes.
(6) I nstal l the cool ant reserve/overfl ow bottl e.
(7) I nstal l the PCM.
(8) Connect the rear fl oor heat duct to the center
adaptor. Check that the carpet i s not i nterferi ng wi th
any duct outl ets.
(9) Pl ug i n the heater-A/C housi ng wi re harness
connectors.
(10) I nstal l the i nstrument panel . Refer to Group
8E - I nstrument Panel Systems for the procedures.
(11) Fi l l the cool i ng system. Refer to Group 7 -
Cool i ng System for the procedures.
(12) Evacuate and charge the refri gerant system
as descri bed i n thi s group.
(13) Connect the battery negati ve cabl e.
(14) Start the vehi cl e and check for proper opera-
ti on of the heati ng and ai r condi ti oni ng systems.
HEATER CORE
REMOVAL
(1) Remove the heater-A/C housi ng as descri bed i n
thi s group.
(2) Remove the screws that secure the heater core
to the heater-A/C housi ng.
(3) Pul l the heater core strai ght out of the housi ng
(Fi g. 59).
INSTALLATION
(1) I nstal l the heater core i nto the heater-A/C
housi ng.
Fig. 56 Heater-A/C Housing
EVAPORATORLINES HEATER CORE LINES HEATER AND A/C UNIT BODY ASSEM- BLY
Fig. 57 Rear Floor Heat Duct
CENTER ADAPTOR HEAT DUCT FWD REAR FLOOR HEAT DUCT
Fig. 58 Heater A/C Housing Remove/Install
BODY ASSEMBLY FWD HEATER A/C UNIT
ZG HEATING AND AIR CONDITIONING 24 - 47
REMOVAL AND INSTALLATION (Continued)
(2) Posi ti on the retai ner cl i ps over the heater core
tubes. I nstal l and ti ghten the screws that secure the
heater core i n the heater-A/C housi ng.
(3) I nstal l the heater-A/C housi ng as descri bed i n
thi s group.
EVAPORATOR COIL
REMOVAL
(1) Remove the heater-A/C housi ng as descri bed i n
thi s group.
(2) Turn the heater-A/C housi ng upsi de down.
(3) Remove the screws that secure the two housi ng
hal ves together. Unsnap the center heat duct adaptor
from the l ower housi ng and remove the screw hi dden
by the adaptor.
(4) Careful l y turn the heater-A/C housi ng over.
Remove the top hal f of the housi ng (Fi g. 60).
(5) Li ft the evaporator coi l from the heater-A/C
housi ng.
INSTALLATION
(1) Posi ti on the evaporator coi l i n the bottom hal f
of the heater-A/C housi ng.
(2) Posi ti on the top hal f of the heater-A/C housi ng
over the bottom hal f. Careful l y turn the housi ng over.
I nstal l and ti ghten the screws that secure the two
housi ng hal ves to each other.
(3) Snap on the center heat duct adaptor.
(4) I nstal l the heater-A/C housi ng as descri bed i n
thi s group.
NOTE: If the evaporator was replaced, add 2
ounces of refrigerant oil to the refrigerant system.
HEAT/DEFROST DOOR ACTUATOR
Thi s actuator i s used onl y on model s equi pped wi th
the standard manual temperature control system.
REMOVAL
(1) Remove the heater-A/C housi ng from the vehi -
cl e as descri bed i n thi s group.
(2) Turn the heater-A/C housi ng upsi de down.
(3) Unpl ug the vacuum harness connector from the
actuator (Fi g. 61).
(4) Separate the door pi vot connecti on from the
door pi vot pi n.
(5) Remove the screws that secure the actuator to
the heater-A/C housi ng.
(6) Remove the heat/defrost door actuator.
INSTALLATION
(1) I nstal l the heat/defrost door actuator.
(2) I nstal l and ti ghten the screws that secure the
actuator to the heater-A/C housi ng.
Fig. 59 Heater Core
HEATER CORE LINES HEATER CORE
Fig. 60 Evaporator Coil Location in Heater-A/
CHousing (Upside Down)
EVAPORATOR LOCATION BOTTOM HALF OF HEATER & A/C UNIT TOP HALF OF HEATER & A/C UNIT
Fig. 61 Heat/Defrost Door Actuator
VACUUM LINE DOOR PIVOT CON- NECTION HEAT/DEFROST DOOR ACTUATOR
24 - 48 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
(3) Press the door pi vot connecti on onto the door
pi vot pi n.
(4) Pl ug i n the vacuum harness connector to the
actuator.
(5) I nstal l the heater-A/C housi ng as descri bed i n
thi s group.
PANEL/DEFROST DOOR ACTUATOR
Thi s actuator i s used onl y on model s equi pped wi th
the standard manual temperature control system.
REMOVAL
(1) Remove the heater-A/C housi ng as descri bed i n
thi s group.
(2) Unpl ug the vacuum harness connector from the
panel /defrost door actuator (Fi g. 62).
(3) Separate the actuator door pi vot connecti on
from the door pi vot pi n.
(4) Remove the screws that secure the actuator to
the heater-A/C housi ng.
(5) Remove the panel /defrost door actuator.
INSTALLATION
(1) I nstal l and ti ghten the screws that secure the
panel /defrost door actuator to the heater-A/C hous-
i ng.
(2) Press the actuator door pi vot connecti on onto
the door pi vot pi n.
(3) Pl ug i n the vacuum harness connector to the
actuator.
(4) I nstal l the heater-A/C housi ng as descri bed i n
thi s group.
HEAT/DEFROST AND PANEL/DEFROST DOOR
MOTOR
These motors are used onl y on model s equi pped
wi th the opti onal Automati c Temperature Control
(ATC) system.
REMOVAL
(1) Remove the heater-A/C housi ng from the vehi -
cl e as descri bed i n thi s group.
(2) Turn the heater-A/C housi ng upsi de down.
(3) Unpl ug the wi re harness connector from the
motor (Fi g. 63).
(4) Remove the screws that secure the motor to the
heater-A/C housi ng.
(5) Remove the motor from the housi ng.
INSTALLATION
(1) Posi ti on the heat/defrost or panel /defrost door
motor on the heater-A/C housi ng.
(2) I nstal l and ti ghten the screws that secure the
motor to the housi ng.
(3) Pl ug i n the wi re harness connector to the
motor.
(4) I nstal l the heater-A/C housi ng as descri bed i n
thi s group.
HEAT/DEFROST DOOR
REMOVAL
(1) Remove the heater-A/C housi ng as descri bed i n
thi s group.
(2) Turn the heater-A/C housi ng upsi de down.
(3) Separate the actuator door pi vot connecti on
from the door pi vot pi n.
(4) Unpl ug the vacuum harness connector from the
actuator, or unpl ug the wi re harness connector from
the motor, as equi pped.
(5) Remove the screws that secure the two hal ves
of the heater-A/C housi ng to each other. Remove the
Fig. 62 Panel/Defrost Door Actuator
VACUUM LINE PANEL/DEFROST ACTUATOR SHAFT RETAINER
Fig. 63 Heat/Defrost - Panel/Defrost DoorMotor
ELECTRICAL CONNECTOR DOOR PIVOT CON- NECTION HEAT/DEFROST DOOR MOTOR
ZG HEATING AND AIR CONDITIONING 24 - 49
REMOVAL AND INSTALLATION (Continued)
center heat duct adaptor to access and remove the
fi nal screw.
(6) Remove the bottom hal f of the heater-A/C hous-
i ng.
(7) Remove the heat/defrost door.
INSTALLATION
(1) Posi ti on the door pi vot pi n i n the pi vot hol e.
(2) Press the actuator door pi vot connecti on onto
the door pi vot pi n.
(3) Posi ti on the top hal f of the heater-A/C housi ng
onto the bottom. Be certai n the door pi vot pi ns al i gn
wi th the pi vot hol es.
(4) Careful l y turn the heater-A/C housi ng over.
I nstal l and ti ghten the screws.
(5) Snap on the center heat duct adaptor.
(6) Pl ug i n the vacuum harness connector to the
actuator, or the wi re harness connector to the motor,
as equi pped.
(7) I nstal l the heater-A/C housi ng as descri bed i n
thi s group.
RECIRCULATING AIR DOOR
REMOVAL
(1) Remove the heater-A/C housi ng as descri bed i n
thi s group.
(2) Remove the reci rcul ati ng ai r door actuator rod
retai ner cl i p.
(3) Pry the reci rcul ati ng ai r door pi vot shaft
retai ner from the shaft.
(4) Remove the reci rcul ati ng ai r door through the
top openi ng of the heater-A/C housi ng.
INSTALLATION
(1) I nstal l the reci rcul ati ng ai r door through the
top openi ng of the heater-A/C housi ng and posi ti on i t
i n pl ace.
(2) Press the reci rcul ati ng ai r door pi vot shaft
retai ner onto the shaft.
(3) Connect the reci rcul ati ng ai r door actuator rod
and retai ner cl i p to the door l ever.
(4) I nstal l the heater-A/C housi ng as descri bed i n
thi s group.
TEMPERATURE/BLEND AIR DOOR
REMOVAL
(1) Remove the heater-A/C housi ng as descri bed i n
thi s group.
(2) Turn the heater-A/C housi ng upsi de down.
(3) Remove the screws securi ng the two housi ng
hal ves to each other. Remove the center heat duct
adaptor to access and remove the fi nal screw.
(4) Remove the bottom hal f of the heater-A/C hous-
i ng.
(5) Remove the temperature control door (Fi g. 64).
NOTE: To reinstall the door-to-motor pivot connec-
tion, the motor must be removed from the heater-
A/C housing as described in this group.
INSTALLATION
(1) I f the door was removed, i nstal l the removed
motor to the pi vot connecti on. Posi ti on the motor on
the heater-A/C housi ng and ti ghten the screws.
(2) I nstal l the temperature control door.
(3) Posi ti on the top hal f of the heater-A/C housi ng
onto the bottom hal f. Be certai n that the door pi vot
pi ns al i gn wi th the pi vot hol es.
(4) Careful l y turn the heater-A/C housi ng over.
I nstal l and ti ghten the screws.
(5) Snap on the center heat duct adaptor.
(6) I nstal l the heater-A/C housi ng as descri bed i n
thi s group.
Fig. 64 Temperature Control (Blend Air) Door
HEAT/DEFROST DOOR TEMP/BLEND AIR DOOR
24 - 50 HEATING AND AIR CONDITIONING ZG
REMOVAL AND INSTALLATION (Continued)
EMISSION CONTROL SYSTEMS
CONTENTS
page page
EVAPORATIVE EMISSION CONTROLS . . . . . . . 13 ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . 1
ON-BOARD DIAGNOSTICS
INDEX
page page
GENERAL INFORMATION
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
CIRCUIT ACTUATION TEST MODE . . . . . . . . . . 2
COMPONENT MONITORS . . . . . . . . . . . . . . . . 11
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . 2
HIGH AND LOW LIMITS . . . . . . . . . . . . . . . . . . 12
LOAD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MALFUNCTION INDICATOR LAMP (MIL) . . . . . . 1
MONITORED SYSTEMS . . . . . . . . . . . . . . . . . . 9
NON-MONITORED CIRCUITS . . . . . . . . . . . . . 11
STATE DISPLAY TEST MODE . . . . . . . . . . . . . . 2
TRIP DEFINITION . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL INFORMATION
SYSTEM DESCRIPTION
The Powertrai n Control Modul e (PCM) moni tors
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a
probl em wi th a moni tored ci rcui t often enough to
i ndi cate an actual probl em, i t stores a Di agnosti c
Troubl e Code (DTC) i n the PCMs memory. I f the
code appl i es to a non-emi ssi ons rel ated component or
system, and the probl em i s repai red or ceases to
exi st, the PCM cancel s the code after 40 warm-up
cycl es. Di agnosti c troubl e codes that affect vehi cl e
emi ssi ons i l l umi nate the Mal functi on I ndi cator
(check engi ne) Lamp. Refer to Mal functi on I ndi cator
Lamp i n thi s secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored
ci rcui t even though a mal functi on has occurred. Thi s
may happen because one of the DTC cri teri a for the
ci rcui t has not been met. For example , assume the
di agnosti c troubl e code cri teri a requi res the PCM to
moni tor the ci rcui t onl y when the engi ne operates
between 750 and 2000 RPM. Suppose the sensors
output ci rcui t shorts to ground when engi ne operates
above 2400 RPM (resul ti ng i n 0 vol t i nput to the
PCM). Because the condi ti on happens at an engi ne
speed above the maxi mum threshol d (2000 rpm), the
PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTCs. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, connect the DRB scan
tool to the 16way data link connector (Fig. 1) to
erase all DTCs and extinguish the MIL.
Techni ci ans can di spl ay stored DTCs by three di f-
ferent methods. Refer to Di agnosti c Troubl e Codes i n
thi s secti on. For DTC i nformati on, refer to charts i n
thi s secti on.
DESCRIPTION AND OPERATION
MALFUNCTION INDICATOR LAMP (MIL)
As a functi onal test, the MI L (check engi ne) i l l umi -
nates at key-on before engi ne cranki ng. Whenever
the Powertrai n Control Modul e (PCM) sets a Di ag-
nosti c Troubl e Code (DTC) that affects vehi cl e emi s-
si ons, i t i l l umi nates the MI L. I f a probl em i s
ZG EMISSION CONTROL SYSTEMS 25 - 1
detected, the PCM sends a message to the i nstru-
ment cl uster to i l l umi nate the l amp. The PCM i l l u-
mi nates the MI L onl y for DTCs that affect vehi cl e
emi ssi ons. There are some moni tors that may take
two consecuti ve tri ps, wi th a detected faul t, before
the MI L i s i l l umi nated. The MI L stays on conti nu-
ousl y when the PCM has entered a Li mp-I n mode or
i denti fi ed a fai l ed emi ssi on component. Refer to the
Di agnosti c Troubl e Code charts i n thi s group for
emi ssi on rel ated codes.
Al so, the MI L ei ther fl ashes or i l l umi nates conti n-
uousl y when the PCM detects acti ve engi ne mi sfi re.
Refer to Mi sfi re Moni tori ng i n thi s secti on.
Addi ti onal l y, the PCM may reset (turn off) the MI L
when one of the fol l owi ng occur:
PCM does not detect the mal functi on for 3 con-
secuti ve tri ps (except mi sfi re and Fuel system Moni -
tors).
PCM does not detect a mal functi on whi l e per-
formi ng three successi ve engi ne mi sfi re or fuel sys-
tem tests. The PCM performs these tests whi l e the
engi ne i s operati ng wi thi n 375 RPM of and wi thi n
10 % of the l oad of the operati ng condi ti on at whi ch
the mal functi on was fi rst detected.
STATE DISPLAY TEST MODE
The swi tch i nputs to the Powertrai n Control Mod-
ul e (PCM) have two recogni zed states; HI GH and
LOW. For thi s reason, the PCM cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus
an open ci rcui t, a short ci rcui t, or a defecti ve swi tch.
I f the State Di spl ay screen shows the change from
HI GH to LOW or LOW to HI GH, assume the enti re
swi tch ci rcui t to the PCM functi ons properl y. Connect
the DRB scan tool to the data l i nk connector and
access the state di spl ay screen. Then access ei ther
State Di spl ay I nputs and Outputs or State Di spl ay
Sensors.
CIRCUIT ACTUATION TEST MODE
The Ci rcui t Actuati on Test Mode checks for proper
operati on of output ci rcui ts or devi ces the Powertrai n
Control Modul e (PCM) may not i nternal l y recogni ze.
The PCM attempts to acti vate these outputs and
al l ow an observer to veri fy proper operati on. Most of
the tests provi de an audi bl e or vi sual i ndi cati on of
devi ce operati on (cl i ck of rel ay contacts, fuel spray,
etc.). Except for i ntermi ttent condi ti ons, i f a devi ce
functi ons properl y duri ng testi ng, assume the devi ce,
i ts associ ated wi ri ng, and dri ver ci rcui t work cor-
rectl y. Connect the DRB scan tool to the data l i nk
connector and access the Actuators screen.
DIAGNOSTIC TROUBLE CODES
A Di agnosti c Troubl e Code (DTC) i ndi cates the
PCM has recogni zed an abnormal condi ti on i n the
system.
The techni ci an can retri eve and di spl ay DTCs i n
three di fferent ways:
The preferred and most accurate method of
retri evi ng a DTC i s by usi ng the DRB scan tool . The
scan tool suppl i es detai l ed di agnosti c i nformati on
whi ch can be used to more accuratel y di agnose
causes for a DTC.
The second method i s by observi ng the two-di gi t
number di spl ayed at the Mal functi on I ndi cator Lamp
(MI L). The MI L i s di spl ayed on the i nstrument panel
as the Check Engi ne l amp. Thi s method i s to be used
as a qui ck-test onl y. Al ways use the DRB scan tool
for detai l ed i nformati on.
The thi rd method i s by observi ng the two-di gi t
number di spl ayed at the vehi cl e odometer. Thi s
method, si mi l ar to the MI L l amp, i s al so to be used
as a qui ck-test onl y.
Remember that DTCs are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTCs, refer to the charts in this
section.
BULB CHECK
Each ti me the i gni ti on key i s turned to the ON
posi ti on, the mal functi on i ndi cator (check engi ne)
l amp on the i nstrument panel shoul d i l l umi nate for
approxi matel y 2 seconds then go out. Thi s i s done for
a bul b check.
OBTAINING DTCS USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data l i nk
(di agnosti c) connector. Thi s connector i s l ocated i n
Fig. 1 Data Link (Diagnostic) ConnectorLocation
HEADLAMPSWITCH DATA LINK CONNECTOR (LEFT SIDE OF COLUMN ABOVE BRAKE PEDAL)
25 - 2 EMISSION CONTROL SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
the passenger compartment; at the l ower edge of
i nstrument panel ; near the steeri ng col umn.
(2) Turn the i gni ti on swi tch on and access the
Read Faul t screen.
(3) Record al l the DTCs and freeze frame i nfor-
mati on shown on the DRB scan tool .
(4) To erase DTCs, use the Erase Troubl e Code
data screen on the DRB scan tool . Do not erase any
DTCs until problems have been investigated
and repairs have been performed.
OBTAINING DTCS USING MIL LAMP
(1) Cycl e the i gni ti on key On - Off - On - Off - On
wi thi n 5 seconds.
(2) Count the number of ti mes the MI L (check
engi ne l amp) on the i nstrument panel fl ashes on and
off. The number of fl ashes represents the troubl e
code. There i s a sl i ght pause between the fl ashes rep-
resenti ng the fi rst and second di gi ts of the code.
Longer pauses separate i ndi vi dual two di gi t troubl e
codes.
An exampl e of a fl ashed DTC i s as fol l ows:
Lamp fl ashes 4 ti mes, pauses, and then fl ashes
6 more ti mes. Thi s i ndi cates a DTC code number 46.
Lamp fl ashes 5 ti mes, pauses, and fl ashes 5
more ti mes. Thi s i ndi cates a DTC code number 55. A
DTC 55 wi l l al ways be the l ast code to be di spl ayed.
Thi s i ndi cates the end of al l stored codes.
OBTAINING DTCS USING VEHICLE
ODOMETER
(1) Cycl e the i gni ti on key On - Off - On - Off - On
wi thi n 5 seconds.
(2) After a short pause, the mi l eage shown on the
vehi cl es di gi tal odometer wi l l be temporari l y del eted.
After thi s occurs, read the DTC number di spl ayed on
the odometer. Each twodi gi t number wi l l be di s-
pl ayed wi th a sl i ght del ay between numbers.
(3) A DTC number 55 wi l l al ways be the l ast code
to be di spl ayed. Thi s i ndi cates the end of al l stored
codes. After code 55 has been di spl ayed, the odometer
wi l l return to i ts normal mode.
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
DESCRIPTION OF DIAGNOSTIC TROUBLE
CODE
12* Battery Disconnect Direct battery input to PCM was disconnected within
the last 50 Key-on cycles.
55* Completion of fault code display on Check Engine
lamp.
01 54** P0340 No Cam Signal at PCM No camshaft signal detected during engine
cranking.
02 53** P0601 Internal Controller
Failure
PCM Internal fault condition detected.
05 47*** Charging System
Voltage Too Low
Battery voltage sense input below target charging
during engine operation. Also, no significant change
detected in battery voltage during active test of
generator output circuit.
06 46*** Charging System
Voltage Too High
Battery voltage sense input above target charging
voltage during engine operation.
0A 42* Auto Shutdown Relay
Control Circuit
An open or shorted condition detected in the auto
shutdown relay circuit.
0B 41*** Generator Field Not
Switching Properly
An open or shorted condition detected in the
generator field control circuit.
0C 37** P0743 Torque Converter Clutch
Soleniod/Trans Relay
Circuits
An open or shorted condition detected in the torque
converter part throttle unlock solenoid control circuit
(3 speed auto RH trans. only).
0E 35** P1491 Rad Fan Control Relay
Circuit
An open or shorted condition detected in the low
speed radiator fan relay control circuit.
ZG EMISSION CONTROL SYSTEMS 25 - 3
DESCRIPTION AND OPERATION (Continued)
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
DESCRIPTION OF DIAGNOSTIC TROUBLE
CODE
0F 34* Speed Control Solenoid
Circuits
An open or shorted condition detected in the Speed
Control vacuum or vent solenoid circuits.
10 33* A/C Clutch Relay Circuit An open or shorted condition detected in the A/C
clutch relay circuit.
12 31** P0443 EVAP Purge Solenoid
Circuit
An open or shorted condition detected in the duty
cycle purge solenoid circuit.
13 27** P0203 Injector #3 Control
Circuit
Injector #3 output driver does not respond properly
to the control signal.
or
14 P0202 Injector #2 Control
Circuit
Injector #2 output driver does not respond properly
to the control signal.
or
15 P0201 Injector #1 Control
Circuit
Injector #1 output driver does not respond properly
to the control signal.
19 25** P0505 Idle Air Control Motor
Circuits
A shorted or open condition detected in one or
more of the idle air control motor circuits.
1A 24** P0122 Throttle Position Sensor
Voltage Low
Throttle position sensor input below the minimum
acceptable voltage
or
1B P0123 Throttle Position Sensor
Voltage High
Throttle position sensor input above the maximum
acceptable voltage.
1E 22** P0117 ECT Sensor Voltage
Too Low
Engine coolant temperature sensor input below
minimum acceptable voltage.
or
1F P0118 ECT Sensor Voltage
Too High
Engine coolant temperature sensor input above
maximum acceptable voltage.
21 17* Engine Is Cold Too
Long
Engine did not reach operating temperature within
acceptable limits.
23 15** P0500 No Vehicle Speed
Sensor Signal
No vehicle speed sensor signal detected during
road load conditions.
24 14** P0107 MAP Sensor Voltage
Too Low
MAP sensor input below minimum acceptable
voltage.
or
25 P0108 MAP Sensor Voltage
Too High
MAP sensor input above maximum acceptable
voltage.
27 13** P1297 No Change in MAP
From Start to Run
No difference recognized between the engine MAP
reading and the barometric (atmospheric) pressure
reading from start-up.
28 11* No Crank Reference
Signal at PCM
No crank reference signal detected during engine
cranking.
2B P0351 Ignition Coil #1 Primary
Circuit
Peak primary circuit current not achieved with
maximum dwell time.
2C 42* No ASD Relay Output
Voltage at PCM
An Open condition Detected In The ASD Relay
Output Circuit.
25 - 4 EMISSION CONTROL SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
DESCRIPTION OF DIAGNOSTIC TROUBLE
CODE
31 63** P1696 PCM Failure EEPROM
Write Denied
Unsuccessful attempt to write to an EEPROM
location by the PCM.
32 37** P0753 Trans 3-4 Shift
Sol/Trans Relay Circuits
Current state of output port for the solenoid is
different from expected state.
39 23** P0112 Intake Air Temp Sensor
Voltage Low
Intake air temperature sensor input below the
maximum acceptable voltage.
or
3A P0113 Intake Air Temp Sensor
Voltage High
Intake air temperature sensor input above the
minimum acceptable voltage.
3D 27** P0204 Injector #4 Control
Circuit
Injector #4 output driver does not respond properly
to the control signal.
3E 21** P0132 Left Upstream O2S
Shorted to Voltage
Oxygen sensor input voltage maintained above the
normal operating range.
44 53** PO600 PCM Failure SPI
Communications
PCM internal fault condition detected
45 27** P0205 Injector #5 Control
Circuit
Injector #5 output driver does not respond properly
to the control signal.
or
46 P0206 Injector #6 Control
Circuit
Injector #6 output driver does not respond properly
to the control signal.
4A 45* P0712 Trans Temp Sensor
Voltage Too Low
Voltage less than 1.55 volts.
or
4B P0713 Trans Temp Sensor
Voltage Too High
Voltage greater than 3.76 volts.
4F 27** P0207 Injector #7 Control
Circuit
Injector #7 output driver does not respond properly
to the control signal.
or
50 P0208 Injector #8 Control
Circuit
Injector #8 output driver does not respond properly
to the control signal.
52 77* SPD CTRL PWR RLY;
or S/C 12V Driver CKT
Malfuntion detected with power feed to speed
control servo solenoids
56 34* Speed Control Switch
Always High
Speed control switch input above the maximum
acceptable voltage.
or
57 Speed Control Switch
Always Low
Speed control switch input below the minimum
acceptable voltage.
65 42* Fuel Pump Relay
Control Circuit
An open or shorted condition detected in the fuel
pump relay control circuit.
66 21** P0133 Left Upstream O2S
Slow Response
Oxygen sensor response slower than minimum
required switching frequency.
or
67 P0135 Left Upstream O2S
Heater Failure
Upstream oxygen sensor heating element circuit
malfunction
ZG EMISSION CONTROL SYSTEMS 25 - 5
DESCRIPTION AND OPERATION (Continued)
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
DESCRIPTION OF DIAGNOSTIC TROUBLE
CODE
69 P0141 Downstream,Left Bank
Downstream or
Pre-Catalyst Heater
Failure
Oxygen sensor heating element circuit malfunction.
6A 43** P0300 Multiple Cylinder
Mis-fire
Misfire detected in multiple cylinders.
or
6B P0301 Cylinder #1 Mis-fire Misfire detected in cylinder #1.
or
6C P0302 Cylinder #2 Mis-fire Misfire detected in cylinder #2.
or
6D P0303 Cylinder #3 Mis-fire Misfire detected in cylinder #3.
or
6E P0304 Cylinder #4 Mis-fire Misfire detected in cylinder #4.
70 72** P0420 Left Bank Catalytic (or
just) Catalytic Efficency
Failure
Catalyst efficiency below required level.
71 31* P0441 Evap Purge Flow
Monitor Failure
Insufficient or excessive vapor flow detected during
evaporative emission system operation.
72 37** P1899 P/N Switch Stuck in
Park or in Gear
Incorrect input state detected for the Park/Neutral
switch, auto. trans. only.
76 52** P0172 Left Bank or Fuel
System Rich
A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
77 51** P0171 Right Rear (or just) Fuel
System Lean
A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
7E 21** P0138 Left Bank Downstream
or Downstream and
Pre-Catalyst O2S
Shorted to Voltage
Oxygen sensor input voltage maintained above the
normal operating range.
80 17** P0125 Closed Loop Temp Not
Reached
Engine does not reach 20F within 5 minutes with a
vehicle speed signal.
84 24** P0121 TPS Voltage Does Not
Agree With MAP
TPS signal does not correlate to MAP sensor
87 14** P1296 No 5 Volts To MAP
Sensor
5 Volt output to MAP sensor open.
8A 25** P1294 Target Idle Not Reached Actual idle speed does not equal target idle speed.
8D 37 P1756 Governor Pressure Not
Equal to Target @
15-20 PSI
Governor sensor input not between 10 and 25 psi
when requested.
or
8E P1757 Governor Pressure
Above 3 PSI In Gear
With 0 MPH
Governor pressure greater than 3 psi when
requested to be 0 psi.
25 - 6 EMISSION CONTROL SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
DESCRIPTION OF DIAGNOSTIC TROUBLE
CODE
94 37* P0740 Torq Conv Clu, No RPM
Drop At Lockup
Relationship between engine speed and vehicle
speed indicates no torque converter clutch
engagement (auto. trans. only).
95 42* Fuel Level Sending Unit
Volts Too Low
Open circuit between PCM and fuel gauge sending
unit.
or
96 Fuel Level Sending Unit
Volts Too High
Circuit shorted to voltage between PCM and fuel
gauge sending unit.
or
97 Fuel Level Unit No
Change Over Miles
No movement of fuel level sender detected.
99 44** P1493 Ambient/Batt Temp Sen
VoltsToo Low
Battery temperature sensor input voltage below an
acceptable range.
or
9A P1492 Ambient/Batt Temp
Sensor VoltsToo High
Battery temperature sensor input voltage above an
acceptable range.
9B 21** P0131 Left Bank and Upstream
O2S Shorted to Ground
O2 sensor voltage too low, tested after cold start.
or
9C P0137 Downstream, Left Bank
Downstream and
Pre-Catalyst O2S
Shorted to Ground
O2 sensor voltage too low, tested after cold start.
9D 11** P1391 Intermittent Loss of
CMP or CKP
Intermittent loss of either camshaft or crankshaft
position sensor
A0 31** P0442 Evap Leak Monitor
Small Leak Detected
A small leak has been detected by the leak
detection monitor
or
A1 P0455 Evap Leak Monitor
Large Leak Detected
The leak detection monitor is unable to pressurize
Evap system, indicating a large leak.
A4 45 P0711 Trans Temp Sensor, No
Rise After Start
Sump temp did not rise more than 16F within 10
minutes when starting temp is below
40F or sump temp is above 260F with coolant
below 100F.
A5 37** P0783 3-4 Shift Sol, No RPM
Drop @ 3-4 Shift
The ratio of engine rpm/output shaft speed did not
change beyond on the minimum required.
A6 15** P0720 Low Ouput Spd Sensor
RPM Above 15 mph
Output shaft speed is less than 60 rpm with vehicle
speed above 15 mph.
A7 45** P1764 Governor Pessure
Sensor Volts Too Low
Voltage less than .10 volts.
or
A8 P1763 Governor Pressure
Sensor Volts Too HI
Voltage greater than 4.89 volts.
or
ZG EMISSION CONTROL SYSTEMS 25 - 7
DESCRIPTION AND OPERATION (Continued)
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
DESCRIPTION OF DIAGNOSTIC TROUBLE
CODE
A9 P1762 Governor Press Sen
Offset Volts Too Lo or
High
Sensor input greater or less than calibration for 3
consecutive Neutral/Park occurances.
AB 37** P0748 Governor Pressure Sol
Control/Trans Relay
Circuits
Current state of solenoid output port is different
than expected.
AD 37** P1765 Trans 12 Volt Supply
Relay Ctrl Circuit
Current state of solenoid output port is different
than expeted.
AE 43** P0305 Cylinder #5 Mis-fire Misfire detected in cylinder #5.
or
AF P0306 Cylinder #6 Mis-fire Misfire detected in cylinder #6.
or
B0 P0307 Cylinder #7 Mis-fire Misfire detected in cylinder #7.
or
B1 P0308 Cylinder #8 Mis-fire Misfire detected in cylinder #8.
B7 31** P1495 Leak Detection Pump
Solenoid Circuit
Leak detection pump solenoid circuit fault (open or
short)
or
B8 P1494 Leak detection pump
SW or mechanical fault
Leak detection pump switch does not respond to
input.
BA 11** P1398 Mis-fire Adaptive
Numerator at Limit
CKP sensor target windows have too much
variation
BB 31** P1486 Evap leak monitor
pinched hose
found
Plug or pinch detected between purge solenoid and
fuel tank
BC 45 O/D Switch Pressed
(LO) More Than 5 Min
Overdrive Off switch input too low for more than 5
minutes.
CO 21 P0133 CAT MON SLOW O2
1/1
A slow switching oxygen sensor has been detected
in bank 1/1 during catalyst monitor test.
* Check Engi ne Lamp (MI L) wi l l not i l l umi nate i f thi s Di agnosti c Troubl e Code was recorded. Cycl e I gni ti on
key as descri bed i n manual and observe code fl ashed by Check Engi ne l amp.
** Check Engi ne Lamp (MI L) wi l l i l l umi nate duri ng engi ne operati on i f thi s Di agnosti c Troubl e Code was
recorded.
*** Generator Lamp i l l umi nated
25 - 8 EMISSION CONTROL SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
MONITORED SYSTEMS
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator (Check
Engi ne) Lamp wi l l be i l l umi nated. These moni tors
generate Di agnosti c Troubl e Codes that can be di s-
pl ayed wi th the check engi ne l amp or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
Mi sfi re Moni tor
Fuel System Moni tor
Oxygen Sensor Moni tor
Oxygen Sensor Heater Moni tor
Catal yst Moni tor
Al l these system moni tors requi re two consecuti ve
tri ps wi th the mal functi on present to set a faul t.
Fol l owi ng i s a descri pti on of each system moni tor,
and i ts DTC.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
MIL 21OXYGEN SENSOR (O2S) MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
Catal yst and Fuel Moni tors.
The O2S can fai l i n any or al l of the fol l owi ng
manners:
sl ow response rate
reduced output vol tage
dynami c shi ft
shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
MIL 21OXYGEN SENSOR HEATER MONITOR
I f there i s an oxygen sensor (O2S) shorted to vol t-
age DTC, as wel l as a O2S heater DTC, the O2S
faul t MUST be repai red fi rst. Before checki ng the
O2S faul t, veri fy that the heater ci rcui t i s operati ng
correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S sensor
are very temperature sensi ti ve. The readi ngs are not
accurate bel ow 300C. Heati ng of the O2S sensor i s
done to al l ow the engi ne control l er to shi ft to cl osed
l oop control as soon as possi bl e. The heati ng el ement
used to heat the O2S sensor must be tested to ensure
that i t i s heati ng the sensor properl y.
The O2S sensor ci rcui t i s moni tored for a drop i n
vol tage. The sensor output i s used to test the heater
by i sol ati ng the effect of the heater el ement on the
O2S sensor output vol tage from the other effects.
MIL 31LEAK DETECTION PUMP MONITOR
The l eak detecti on assembl y i ncorporates two pri -
mary functi ons: i t must detect a l eak i n the evapora-
ti ve system and seal the evaporati ve system so the
l eak detecti on test can be run.
The pri mary components wi thi n the assembl y are:
A three port sol enoi d that acti vates both of the func-
ti ons l i sted above; a pump whi ch contai ns a swi tch,
two check val ves and a spri ng/di aphragm, a cani ster
vent val ve (CVV) seal whi ch contai ns a spri ng l oaded
vent seal val ve.
I mmedi atel y after a col d start, between predeter-
mi ned temperature threshol ds l i mi ts, the three port
sol enoi d i s bri efl y energi zed. Thi s i ni ti al i zes the
ZG EMISSION CONTROL SYSTEMS 25 - 9
DESCRIPTION AND OPERATION (Continued)
pump by drawi ng ai r i nto the pump cavi ty and al so
cl oses the vent seal . Duri ng non test condi ti ons the
vent seal i s hel d open by the pump di aphragm
assembl y whi ch pushes i t open at the ful l travel posi -
ti on. The vent seal wi l l remai n cl osed whi l e the
pump i s cycl i ng due to the reed swi tch tri ggeri ng of
the three port sol enoi d that prevents the di aphragm
assembl y from reachi ng ful l travel . After the bri ef
i ni ti al i zati on peri od, the sol enoi d i s de-energi zed
al l owi ng atmospheri c pressure to enter the pump
cavi ty, thus permi tti ng the spri ng to dri ve the di a-
phragm whi ch forces ai r out of the pump cavi ty and
i nto the vent system. When the sol enoi d i s energi zed
and de energi zed, the cycl e i s repeated creati ng fl ow
i n typi cal di aphragm pump fashi on. The pump i s con-
trol l ed i n 2 modes:
Pump Mode: The pump i s cycl ed at a fi xed rate to
achi eve a rapi d pressure bui l d i n order to shorten the
overal l test l ength.
Test Mode: The sol enoi d i s energi zed wi th a fi xed
durati on pul se. Subsequent fi xed pul ses occur when
the di aphragm reaches the Swi tch cl osure poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5 H20.
The cycl e rate of pump strokes i s qui te rapi d as the
system begi ns to pump up to thi s pressure. As the
pressure i ncreases, the cycl e rate starts to drop off. I f
there i s no l eak i n the system, the pump woul d even-
tual l y stop pumpi ng at the equal i zed pressure. I f
there i s a l eak, i t wi l l conti nue to pump at a rate rep-
resentati ve of the fl ow characteri sti c of the si ze of the
l eak. From thi s i nformati on we can determi ne i f the
l eak i s l arger than the requi red detecti on l i mi t (cur-
rentl y set at .040 ori fi ce by CARB). I f a l eak i s
reveal ed duri ng the l eak test porti on of the test, the
test i s termi nated at the end of the test mode and no
further system checks wi l l be performed.
After passi ng the l eak detecti on phase of the test,
system pressure i s mai ntai ned by turni ng on the
LDPs sol enoi d unti l the purge system i s acti vated.
Purge acti vati on i n effect creates a l eak. The cycl e
rate i s agai n i nterrogated and when i t i ncreases due
to the fl ow through the purge system, the l eak check
porti on of the di agnosti c i s compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
Evaporati ve system functi onal i ty wi l l be veri fi ed by
usi ng the stri cter evap purge fl ow moni tor. At an
appropri ate warm i dl e the LDP wi l l be energi zed to
seal the cani ster vent. The purge fl ow wi l l be cl ocked
up from some smal l val ue i n an attempt to see a
shi ft i n the 02 control system. I f fuel vapor, i ndi cated
by a shi ft i n the 02 control , i s present the test i s
passed. I f not, i t i s assumed that the purge system i s
not functi oni ng i n some respect. The LDP i s agai n
turned off and the test i s ended.
MIL 43MISFIRE MONITOR
Excessi ve engi ne mi sfi re resul ts i n i ncreased cata-
l yst temperature and causes an i ncrease i n HC emi s-
si ons. Severe mi sfi res coul d cause catal yst damage.
To prevent catal yti c convertor damage, the PCM
moni tors engi ne mi sfi re.
The Powertrai n Control Modul e (PCM) moni tors
for mi sfi re duri ng most engi ne operati ng condi ti ons
(posi ti ve torque) by l ooki ng at changes i n the crank-
shaft speed. I f a mi sfi re occurs the speed of the
crankshaft wi l l vary more than normal .
MIL 51/52FUEL SYSTEM MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the Ai r Fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S sensor output. The programmed
memory acts as a sel f cal i brati on tool that the engi ne
control l er uses to compensate for vari ati ons i n engi ne
speci fi cati ons, sensor tol erances and engi ne fati gue
over the l i fe span of the engi ne. By moni tori ng the
actual fuel -ai r rati o wi th the O2S sensor (short term)
and mul ti pl yi ng that wi th the program l ong-term
(adapti ve) memory and compari ng that to the l i mi t,
i t can be determi ned whether i t wi l l pass an emi s-
si ons test. I f a mal functi on occurs such that the PCM
cannot mai ntai n the opti mum A/F rati o, then the
MI L wi l l be i l l umi nated.
MIL 64CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. A mel tdown of the cerami c core can
cause a reducti on of the exhaust passage. Thi s can
i ncrease vehi cl e emi ssi ons and deteri orate engi ne
performance, dri veabi l i ty and fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2Ss) to moni tor the effi ci ency of the converter. The
dual O2Ss sensor strategy i s based on the fact that
as a catal yst deteri orates, i ts oxygen storage capaci ty
and i ts effi ci ency are both reduced. By moni tori ng
the oxygen storage capaci ty of a catal yst, i ts effi -
ci ency can be i ndi rectl y cal cul ated. The upstream
O2S i s used to detect the amount of oxygen i n the
exhaust gas before the gas enters the catal yti c con-
25 - 10 EMISSION CONTROL SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
verter. The PCM cal cul ates the A/F mi xture from the
output of the O2S. A l ow vol tage i ndi cates hi gh oxy-
gen content (l ean mi xture). A hi gh vol tage i ndi cates a
l ow content of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstream O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2Ss.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2Ss i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L (check
engi ne l amp) wi l l be i l l umi nated.
TRIP DEFINITION
The term Tri p has di fferent meani ngs dependi ng
on what the ci rcumstances are. I f the MI L (Mal func-
ti on I ndi cator Lamp) i s OFF, a Tri p i s defi ned as
when the Oxygen Sensor Moni tor and the Catal yst
Moni tor have been compl eted i n the same dri ve cycl e.
When any Emi ssi on DTC i s set, the MI L on the
dash i s turned ON. When the MI L i s ON, i t takes 3
good tri ps to turn the MI L OFF. I n thi s case, i t
depends on what type of DTC i s set to know what a
Tri p i s.
For the Fuel Moni tor or Mi s-Fi re Moni tor (conti n-
uous moni tor), the vehi cl e must be operated i n the
Si mi l ar Condi ti on Wi ndow for a speci fi ed amount of
ti me to be consi dered a Good Tri p.
I f a Non-Conti uous OBDI I Moni tor, such as:
Oxygen Sensor
Catal yst Moni tor
Purge Fl ow Moni tor
Leak Detecti on Pump Moni tor (i f equi pped)
EGR Moni tor (i f equi pped)
Oxygen Sensor Heater Moni tor
fai l s twi ce i n a row and turns ON the MI L, re-run-
ni ng that moni tor whi ch previ ousl y fai l ed, on the
next start-up and passi ng the moni tor i s consi dered
to be a Good Tri p.
I f any other Emi ssi on DTC i s set (not an OBDI I
Moni tor), a Good Tri p i s consi dered to be when the
Oxygen Sensor Moni tor and Catal yst Moni tor have
been compl eted; or 2 Mi nutes of engi ne run ti me i f
the Oxygen Sensor Moni tor or Catal yst Moni tor have
been stopped from runni ng.
I t can take up to 2 Fai l ures i n a row to turn on the
MI L. After the MI L i s ON, i t takes 3 Good Tri ps to
turn the MI L OFF. After the MI L i s OFF, the PCM
wi l l sel f-erase the DTC after 40 Warm-up cycl es. A
Warm-up cycl e i s counted when the ECT (Engi ne
Cool ant Temperature Sensor) has crossed 160F and
has ri sen by at l east 40F si nce the engi ne has been
started.
COMPONENT MONITORS
There are several components that wi l l affect vehi -
cl e emi ssi ons i f they mal functi on. I f one of these com-
ponents mal functi ons the Mal functi on I ndi cator
Lamp (Check Engi ne) wi l l i l l umi nate.
Some of the component moni tors are checki ng for
proper operati on of the part. El ectri cal l y operated
components now have i nput (rati onal i ty) and output
(functi onal i ty) checks. Previ ousl y, a component l i ke
the Throttl e Posi ti on sensor (TPS) was checked by
the PCM for an open or shorted ci rcui t. I f one of
these condi ti ons occurred, a DTC was set. Now there
i s a check to ensure that the component i s worki ng.
Thi s i s done by watchi ng for a TPS i ndi cati on of a
greater or l esser throttl e openi ng than MAP and
engi ne rpm i ndi cate. I n the case of the TPS, i f engi ne
vacuum i s hi gh and engi ne rpm i s 1600 or greater
and the TPS i ndi cates a l arge throttl e openi ng, a
DTC wi l l be set. The same appl i es to l ow vacuum i f
the TPS i ndi cates a smal l throttl e openi ng.
Al l open/short ci rcui t checks or any component that
has an associ ated l i mp i n wi l l set a faul t after 1 tri p
wi th the mal functi on present. Components wi thout
an associ ated l i mp i n wi l l take two tri ps to i l l umi -
nate the MI L.
Refer to the Di agnosti c Troubl e Codes Descri pti on
Charts i n thi s secti on and the appropri ate Power-
trai n Di agnosti c Procedure Manual for di agnosti c
procedures.
NON-MONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems and condi ti ons that coul d have mal functi ons
causi ng dri veabi l i ty probl ems. The PCM mi ght not
store di agnosti c troubl e codes for these condi ti ons.
However, probl ems wi th these systems may cause the
ZG EMISSION CONTROL SYSTEMS 25 - 11
DESCRIPTION AND OPERATION (Continued)
PCM to store di agnosti c troubl e codes for other sys-
tems or components. For exampl e, a fuel pressure
probl em wi l l not regi ster a faul t di rectl y, but coul d
cause a ri ch/l ean condi ti on or mi sfi re. Thi s coul d
cause the PCM to store an oxygen sensor or mi sfi re
di agnosti c troubl e code
FUEL PRESSURE
The fuel pressure regul ator control s fuel system
pressure. The PCM cannot detect a cl ogged fuel
pump i nl et fi l ter, cl ogged i n-l i ne fuel fi l ter, or a
pi nched fuel suppl y or return l i ne. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng the
PCM to store an oxygen sensor or fuel system di ag-
nosti c troubl e code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an i noperati ve i gni ti on coi l ,
foul ed or worn spark pl ugs, i gni ti on cross fi ri ng, or
open spark pl ug cabl es.
CYLINDER COMPRESSION
The PCM cannot detect uneven, l ow, or hi gh engi ne
cyl i nder compressi on.
EXHAUST SYSTEM
The PCM cannot detect a pl ugged, restri cted or
l eaki ng exhaust system, al though i t may set a fuel
system faul t.
FUEL INJ ECTOR MECHANICAL
MALFUNCTIONS
The PCM cannot determi ne i f a fuel i njector i s
cl ogged, the needl e i s sti cki ng or i f the wrong i njector
i s i nstal l ed. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng the PCM to store a di agnosti c
troubl e code for ei ther mi sfi re, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Al though the PCM moni tors engi ne exhaust oxygen
content when the system i s i n cl osed l oop, i t cannot
determi ne excessi ve oi l consumpti on.
THROTTLE BODY AIR FLOW
The PCM cannot detect a cl ogged or restri cted ai r
cl eaner i nl et or fi l ter el ement.
VACUUM ASSIST
The PCM cannot detect l eaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces. However, these coul d cause the PCM
to store a MAP sensor di agnosti c troubl e code and
cause a hi gh i dl e condi ti on.
PCM SYSTEM GROUND
The PCM cannot determi ne a poor system ground.
However, one or more di agnosti c troubl e codes may
be generated as a resul t of thi s condi ti on. The mod-
ul e shoul d be mounted to the body at al l ti mes, al so
duri ng di agnosti c.
PCM CONNECTOR ENGAGEMENT
The PCM may not be abl e to determi ne spread or
damaged connector pi ns. However, i t mi ght store
di agnosti c troubl e codes as a resul t of spread connec-
tor pi ns.
HIGH AND LOW LIMITS
The PCM compares i nput si gnal vol tages from each
i nput devi ce wi th establ i shed hi gh and l ow l i mi ts for
the devi ce. I f the i nput vol tage i s not wi thi n l i mi ts
and other cri teri a are met, the PCM stores a di agnos-
ti c troubl e code i n memory. Other di agnosti c troubl e
code cri teri a mi ght i ncl ude engi ne RPM l i mi ts or
i nput vol tages from other sensors or swi tches that
must be present before veri fyi ng a di agnosti c troubl e
code condi ti on.
LOAD VALUE
ENGINE IDLE/NEUTRAL 2500 RPM/NEUTRAL
All Engines 2% to 8% of Maximum Load 9% to 17% of Maximum Load
25 - 12 EMISSION CONTROL SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
EVAPORATIVE EMISSION CONTROLS
INDEX
page page
DESCRIPTION AND OPERATION
CRANKCASE BREATHER/FILTER5.2L/5.9L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CRANKCASE VENTILATION (CCV) SYSTEM
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 16
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EVAPORATION (EVAP) CANISTER . . . . . . . . . 13
EVAPORATION CONTROL SYSTEM . . . . . . . . 13
LEAK DETECTION PUMP (LDP)WITH
CALIFORNIA EMISSIONS PACKAGE . . . . . . 14
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM5.2L/5.9L ENGINE . . . . . . . . . . . . 15
ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . . 13
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING
LEAK DETECTION PUMP (LDP) . . . . . . . . . . . 18
PCV VALVE TEST5.2L/5.9L ENGINE . . . . . . . 17
VACUUM SCHEMATICS . . . . . . . . . . . . . . . . . . 18
REMOVAL AND INSTALLATION
EVAPORATIVE (EVAP) CANISTER . . . . . . . . . . 18
EVAPORATIVE CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LEAK DETECTION PUMP (LDP) . . . . . . . . . . . 19
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When
fuel evaporates i n the fuel tank, the vapors pass
through vent hoses or tubes to a charcoal fi l l ed evap-
orati ve cani ster. The cani ster temporari l y hol ds the
vapors. The Powertrai n Control Modul e (PCM) al l ows
i ntake mani fol d vacuum to draw vapors i nto the com-
busti on chambers duri ng certai n operati ng condi -
ti ons.
Al l engi nes use a duty cycl e purge system. The
PCM control s vapor fl ow by operati ng the duty cycl e
EVAP purge sol enoi d. Refer to Duty Cycl e EVAP
Cani ster Purge Sol enoi d i n thi s secti on.
When equi pped wi th the Cal i forni a Emi ssi ons
Package, a Leak Detecti on Pump (LDP) wi l l be used
as part of the evaporati ve system. Thi s pump i s used
as part of OBD I I requi rements. Refer to Leak Detec-
ti on Pump i n thi s group for addi ti onal i nformati on.
NOTE: The evaporative system uses specially man-
ufactured hoses. If replacement becomes neces-
sary, only use fuel resistant hose.
ROLLOVER VALVE
The fuel tank i s equi pped wi th a rol l over val ve.
The val ve i s l ocated on the top of the fuel tank (Fi g.
1). The val ve wi l l prevent fuel fl ow through the fuel
tank vent (EVAP) hoses i n the event of an acci dental
vehi cl e rol l over. The EVAP cani ster draws fuel vapors
from the fuel tank through thi s val ve.
The val ve cannot be servi ced separatel y. I f repl ace-
ment i s necessary, the fuel tank must be repl aced.
Refer to Fuel Tank removal and i nstal l ati on i n thi s
group.
EVAPORATION (EVAP) CANISTER
A mai ntenance free, EVAP cani ster i s used on al l
vehi cl es. The EVAP cani ster i s l ocated bel ow the l eft
front headl amp (Fi g. 2). The EVAP cani ster i s fi l l ed
wi th granul es of an acti vated carbon mi xture. Fuel
vapors enteri ng the EVAP cani ster are absorbed by
the charcoal granul es.
Fig. 1 Rollover Valve Location
FRONT ALIGNMENT ARROW (12 OCLOCK) ELECTRICAL PIGTAIL HAR- NESS ROLLOVER VALVE LOCKNUT FUEL FILTER/FUEL PRES- SURE REGULATOR RETAINER CLAMP EVAP CANISTER VENT LINE FUEL PUMP MODULE FUEL SUPPLY TUBE
ZG EMISSION CONTROL SYSTEMS 25 - 13
Fuel tank pressure vents i nto the EVAP cani ster.
Fuel vapors are temporari l y hel d i n the cani ster unti l
they can be drawn i nto the i ntake mani fol d. The duty
cycl e EVAP cani ster purge sol enoi d al l ows the EVAP
cani ster to be purged at predetermi ned ti mes and at
certai n engi ne operati ng condi ti ons.
For vehi cl es equi pped wi th the Cal i forni a Emi ssi on
Package, al so refer to Leak Detecti on Pump i n thi s
group for addi ti onal i nformati on.
DUTY CYCLE EVAP CANISTER PURGE SOLENOID
The 4.0L si x-cyl i nder and 5.2L/5.9L V-8 engi nes
are equi pped wi th a duty cycl e EVAP cani ster purge
sol enoi d. The sol enoi d regul ates the rate of vapor
fl ow from the EVAP cani ster to the i ntake mani fol d.
The Powertrai n Control Modul e (PCM) operates the
sol enoi d.
Duri ng the col d start warm-up peri od and the hot
start ti me del ay, the PCM does not energi ze the sol e-
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The engi ne enters cl osed l oop operati on after i t
reaches a speci fi ed temperature and the ti me del ay
ends. Duri ng cl osed l oop operati on, the PCM cycl es
(energi zes and de-energi zes) the sol enoi d 5 or 10
ti mes per second, dependi ng upon operati ng condi -
ti ons. The PCM vari es the vapor fl ow rate by chang-
i ng sol enoi d pul se wi dth. Pul se wi dth i s the amount
of ti me that the sol enoi d i s energi zed. The PCM
adjusts sol enoi d pul se wi dth based on engi ne operat-
i ng condi ti on.
The sol enoi d attaches to a bracket l ocated on the
l eft/i nner fender (Fi g. 3).
LEAK DETECTION PUMP (LDP)WITH
CALIFORNIA EMISSIONS PACKAGE
The l eak detecti on pump (LDP) i s used wi th 4.0L
6cyl i nder and 5.2L V-8 engi nes i f equi pped wi th the
Cal i forni a Emi ssi on Package. I t i s not used wi th the
5.9L engi ne.
The LDP i s a devi ce used to detect a l eak i n the
evaporati ve system.
The pump contai ns a 3 port sol enoi d, a pump that
contai ns a swi tch, a spri ng l oaded cani ster vent val ve
seal , 2 check val ves and a spri ng/di aphragm.
I mmedi atel y after a col d start, engi ne temperature
between 40F and 86F, the 3 port sol enoi d i s bri efl y
energi zed. Thi s i ni ti al i zes the pump by drawi ng ai r
i nto the pump cavi ty and al so cl oses the vent seal .
Duri ng non-test test condi ti ons, the vent seal i s hel d
open by the pump di aphragm assembl y whi ch pushes
i t open at the ful l travel posi ti on. The vent seal wi l l
remai n cl osed whi l e the pump i s cycl i ng. Thi s i s due
to the operati on of the 3 port sol enoi d whi ch prevents
the di aphragm assembl y from reachi ng ful l travel .
After the bri ef i ni ti al i zati on peri od, the sol enoi d i s
de-energi zed, al l owi ng atmospheri c pressure to enter
the pump cavi ty. Thi s permi ts the spri ng to dri ve the
di aphragm whi ch forces ai r out of the pump cavi ty
and i nto the vent system. When the sol enoi d i s ener-
gi zed and de-energi zed, the cycl e i s repeated creati ng
fl ow i n typi cal di aphragm pump fashi on. The pump
i s control l ed i n 2 modes:
Fig. 2 EVAP Canister Location
MOUNTING NUTS (4) LEFT FRONT FENDER EVAP CANISTER
Fig. 3 Duty Cycle EVAP Purge Solenoid Location
WINDSHIELD WASHER RES- ERVOIR BOTTLE LEFT FRONT FENDER ELECTRICAL CONNECTOR BRACKET MOUNTING NUTS (2) DUTY CYCLE EVAP CANISTER PURGE SOLENOID
25 - 14 EMISSION CONTROL SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
PUMP MODE: The pump i s cycl ed at a fi xed rate
to achi eve a rapi d pressure bui l d i n order to shorten
the overal l test ti me.
TEST MODE: The sol enoi d i s energi zed wi th a
fi xed durati on pul se. Subsequent fi xed pul ses occur
when the di aphragm reaches the swi tch cl osure
poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5 i nches
of water.
When the pump starts, the cycl e rate i s qui te hi gh.
As the system becomes pressuri zed pump rate drops.
I f there i s no l eak the pump wi l l qui t. I f there i s a
l eak, the test i s termi nated at the end of the test
mode.
I f there i s no l eak, the purge moni tor i s run. I f the
cycl e rate i ncreases due to the fl ow through the
purge system, the test i s passed and the di agnosti c i s
compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM5. 2L/5. 9L ENGINE
The 5.2L/5.9L V-8 engi ne i s equi pped wi th a cl osed
crankcase venti l ati on system and a posi ti ve crank-
case venti l ati on (PCV) val ve. The 4.0L 6cyl i nder
engi ne i s not equi pped wi th a PCV val ve. Refer to
Crankcase Venti l ati on System4.0L Engi ne for
i nformati on.
Thi s system consi sts of a crankcase PCV val ve
mounted on the cyl i nder head (val ve) cover wi th a
hose extendi ng from the val ve to the i ntake mani fol d.
Fig. 4 Evaporative System Monitor SchematicTypical
DUTY CYCLE PURGE SOLENOID (DCPS) DRIVER POWERTRAIN CONTROL MODULE (PCM) 3-PORT SOLENOID DRIVER REMOTE FILTER COMBINED CANISTER VENT VALVE & LEAK DETECTION PUMP CANISTER TANK ROLLOVER VALVE & VAPOR FLOW CONTROL ORIFICE INTAKE MANIFOLDTHROTTLE BODY DCPS SWITCH SIGNAL INPUT TO THE PCM ENGINE VACUUM LINE
Fig. 5 PCV Valve/HoseTypical
PCV VALVE PCV VALVE HOSE CONNEC- TIONS
ZG EMISSION CONTROL SYSTEMS 25 - 15
DESCRIPTION AND OPERATION (Continued)
A cl osed engi ne crankcase breather/fi l ter, wi th a
hose connecti ng i t to the ai r cl eaner housi ng, pro-
vi des the source of ai r for system.
The PCV system operates by engi ne i ntake mani -
fol d vacuum (Fi g. 6). Fi l tered ai r i s routed i nto the
crankcase through the ai r cl eaner hose and crank-
case breather/fi l ter. The metered ai r, al ong wi th
crankcase vapors, are drawn through the PCV val ve
and i nto a passage i n the i ntake mani fol d. The PCV
system manages crankcase pressure and meters bl ow
by gases to the i ntake system, reduci ng engi ne
sl udge formati on.
The PCV val ve contai ns a spri ng l oaded pl unger.
Thi s pl unger meters the amount of crankcase vapors
routed i nto the combusti on chamber based on i ntake
mani fol d vacuum.
When the engi ne i s not operati ng or duri ng an
engi ne pop-back, the spri ng forces the pl unger back
agai nst the seat. Thi s wi l l prevent vapors from fl ow-
i ng through the val ve.
Duri ng peri ods of hi gh mani fol d vacuum, such as
i dl e or crui si ng speeds, vacuum i s suffi ci ent to com-
pl etel y compress spri ng. I t wi l l then pul l the pl unger
to the top of the val ve (Fi g. 8). I n thi s posi ti on there
i s mi ni mal vapor fl ow through the val ve.
Duri ng peri ods of moderate mani fol d vacuum, the
pl unger i s onl y pul l ed part way back from i nl et. Thi s
resul ts i n maxi mum vapor fl ow through the val ve
(Fi g. 9).
CRANKCASE VENTILATION (CCV) SYSTEM4. 0L
ENGINE
4.0L 6cyl i nder engi nes are equi pped wi th a
Crankcase Venti l ati on (CCV) system. The CCV sys-
tem performs the same functi on as a conventi onal
PCV system, but does not use a vacuum control l ed
val ve.
A mol ded vacuum tube connects a fi tti ng on the
i ntake mani fol d to a fi xed ori fi ce fi tti ng of a cal i -
brated si ze. Thi s fi tti ng meters the amount of crank-
case vapors drawn out of the engi ne. The fi xed ori fi ce
fi tti ng i s l ocated on the top/rear of cyl i nder head
(val ve) cover (Fi g. 10).
A fresh ai r suppl y hose i s connected between a fi t-
ti ng on the ai r cl eaner housi ng and the ai r i nl et fi t-
ti ng at the top/front of cyl i nder head cover (Fi g. 10).
When the engi ne i s operati ng, fresh ai r enters the
engi ne and mi xes wi th crankcase vapors. Engi ne vac-
uum draws the vapor/ai r mi xture through the fi xed
ori fi ce and i nto the i ntake mani fol d. The vapors are
then consumed duri ng engi ne combusti on.
CRANKCASE BREATHER/FILTER5. 2L/5. 9L
ENGINE
The crankcase breather/fi l ter (Fi g. 11) i s l ocated on
the cyl i nder head (val ve) cover. The fi l ter may be
cl eaned by washi ng i n kerosene or si mi l ar sol vent.
Fi l ter must then be thoroughl y drai ned. More fre-
quent servi ce may be necessary for vehi cl es operated
Fig. 6 Typical Closed Crankcase VentilationSystem
THROTTLE BODY AIR CLEANER AIR INTAKE PCV VALVE COMBUSTION CHAMBER BLOW-BY GASES
CRANKCASE
BREATHER/
FILTER
Fig. 7 Engine Off or Engine Pop-BackNoVapor
Flow
Fig. 8 High Intake Manifold VacuumMinimalVapor
Flow
Fig. 9 Moderate Intake Manifold Vacuum
MaximumVapor Flow
25 - 16 EMISSION CONTROL SYSTEMS ZG
DESCRIPTION AND OPERATION (Continued)
extensi vel y on short run, stop and go or extended
engi ne i dl e servi ce, or extreme dust condi ti ons.
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
Al l vehi cl es are equi pped wi th a combi ned VECI
l abel . Thi s l abel i s l ocated i n the engi ne compart-
ment (Fi g. 12) and contai ns the fol l owi ng:
Engi ne fami l y and di spl acement
Evaporati ve fami l y
Emi ssi on control system schemati c
Certi fi cati on appl i cati on
Engi ne ti mi ng speci fi cati ons (i f adjustabl e)
I dl e speeds (i f adjustabl e)
Spark pl ug and gap
The l abel al so contai ns an engi ne vacuum sche-
mati c. There are uni que l abel s for vehi cl es bui l t for
sal e i n the state of Cal i forni a and the country of
Canada. Canadi an l abel s are wri tten i n both the
Engl i sh and French l anguages. These l abel s are per-
manentl y attached and cannot be removed wi thout
defaci ng i nformati on and destroyi ng l abel .
DIAGNOSIS AND TESTING
PCV VALVE TEST5. 2L/5. 9L ENGINE
(1) Wi th engi ne i dl i ng, remove the PCV val ve from
cyl i nder head (val ve) cover. I f the val ve i s not
pl ugged, a hi ssi ng noi se wi l l be heard as ai r passes
through the val ve. Al so, a strong vacuum shoul d be
fel t at the val ve i nl et (Fi g. 13).
(2) I nstal l the PCV val ve. Remove the crankcase
breather/fi l ter. Hol d a pi ece of sti ff paper, such as a
parts tag, l oosel y over the openi ng of crankcase
Fig. 10 CCV System4.0L Engine
AIR INLET FITTING FIXED ORIFICE FITTING AIR CLEANER COVER
Fig. 11 Crankcase Breather/Filter5.2L/5.9LEngine
AIR INLET FROM AIR CLEANER CYLINDER HEAD COVER MOUNTING NIPPLE
Fig. 12 VECI Label LocationTypical
VECI LABEL
Fig. 13 Check Vacuum at PCV ValveTypical
PCV VALVE GROM- MET PCV HOSE PCV VALVE VACUUM MUST BE FELT AGAINST FINGER ENGINE VALVE COVER
ZG EMISSION CONTROL SYSTEMS 25 - 17
DESCRIPTION AND OPERATION (Continued)
breather/fi l ter at the cyl i nder head (val ve) cover (Fi g.
14).
(3) The paper shoul d be drawn agai nst the openi ng
i n the cyl i nder head (val ve) cover wi th noti ceabl e
force. Thi s wi l l be after al l owi ng approxi matel y one
mi nute for crankcase pressure to reduce.
(4) Turn engi ne off and remove PCV val ve from
cyl i nder head (val ve) cover. The val ve shoul d rattl e
when shaken (Fi g. 15).
(5) Repl ace the PCV val ve and retest the system i f
i t does not operate as descri bed i n the precedi ng
tests. Do not attempt to clean the old PCV valve.
(6) I f the paper i s not hel d agai nst the openi ng i n
cyl i nder head (val ve) cover after new val ve i s
i nstal l ed, the PCV val ve hose may be restri cted and
must be repl aced. The passage i n the i ntake mani fol d
must al so be checked and cl eaned.
(7) To cl ean the i ntake mani fol d fi tti ng, turn a 1/4
i nch dri l l (by hand) through the fi tti ng to di sl odge
any sol i d parti cl es. Bl ow out the fi tti ng wi th shop ai r.
I f necessary, use a smal l er dri l l to avoi d removi ng
any metal from the fi tti ng.
VACUUM SCHEMATICS
A vacuum schemati c for emi ssi on rel ated i tems can
be found on the Vehi cl e Emi ssi on Control I nforma-
ti on (VECI ) Label . Refer to VECI Label i n thi s group
for l abel l ocati on.
LEAK DETECTION PUMP (LDP)
Refer to the appropri ate Powertrai n Di agnosti c
Procedures servi ce manual for LDP testi ng proce-
dures.
REMOVAL AND INSTALLATION
EVAPORATIVE (EVAP) CANISTER
The EVAP cani ster i s l ocated i n the l eft front cor-
ner of vehi cl e bel ow the l eft front headl amp (Fi g. 16).
REMOVAL
(1) Remove the gri l l . Refer to Group 23, Body.
(2) Remove the front bumper/fasci a assembl y.
Refer to Group 23, Body.
(3) Di sconnect vacuum l i nes at cani ster.
(4) Remove the cani ster mounti ng nuts.
(5) Lower the cani ster through bottom of vehi cl e.
Fig. 14 Check Vacuum at Crankcase
BreatherOpeningTypical
CRANKCASE BREATHER OPENING ENGINE VALVE COVER STIFF PAPER PLACED OVER OPENING CRANKCASE BREATHER- REMOVED
Fig. 15 Shake PCV ValveTypical
PCV VALVE GROMMET PCV VALVE PCV VALVE MUST RATTLE WHEN SHAKEN
Fig. 16 EVAP Canister Location
MOUNTING NUTS (4) LEFT FRONT FENDER EVAP CANISTER
25 - 18 EMISSION CONTROL SYSTEMS ZG
DIAGNOSIS AND TESTING (Continued)
INSTALLATION
(1) Posi ti on cani ster to body.
(2) I nstal l cani ster mounti ng nuts. Ti ghten nuts to
9 Nm (80 i n. l bs.) torque.
(3) Connect vacuum l i nes. Be sure vacuum l i nes
are fi rml y connected and not l eaki ng or damaged. I f
l eaki ng, a Di agnosti c Troubl e Code (DTC) may be set
wi th certai n emi ssi on packages.
(4) I nstal l the front bumper/fasci a assembl y and
gri l l . Refer to Group 23, Body.
EVAPORATIVE CANISTER PURGE SOLENOID
REMOVAL
The duty cycl e evaporati ve (EVAP) cani ster purge
sol enoi d i s l ocated i n the l eft/front corner of the
engi ne compartment on al l engi ne/emi ssi on packages
(Fi g. 17).
(1) Di sconnect the el ectri cal connector at the sol e-
noi d.
(2) Di sconnect the vacuum l i nes at the sol enoi d.
(3) Remove the two bracket mounti ng nuts and
remove sol enoi d.
INSTALLATION
(1) Posi ti on the sol enoi d to vehi cl e.
(2) I nstal l and ti ghten the two bracket mounti ng
nuts to 5 Nm (45 i n. l bs.) torque.
(3) Connect the vacuum l i nes to the sol enoi d. Be
sure the vacuum l i nes are fi rml y connected and not
l eaki ng or damaged. I f l eaki ng, a Di agnosti c Troubl e
Code (DTC) may be set wi th certai n emi ssi on pack-
ages.
(4) Connect the el ectri cal connector to the sol enoi d.
ROLLOVER VALVE(S)
The pressure rel i ef/rol l over val ves(s) are/i s mol ded
i nto the fuel tank and are not servi ced separatel y. I f
repl acement i s necessary, the fuel tank must be
repl aced. Refer to Fuel Tank Removal /I nstal l ati on i n
Group 14, Fuel System for procedures.
LEAK DETECTION PUMP (LDP)
The LDP i s l ocated i n the l eft/front corner of the
engi ne compartment bel ow the EVAP cani ster purge
sol enoi d (Fi g. 18).
REMOVAL/INSTALLATION
(1) Remove ai r cl eaner housi ng. Refer to Group 14,
Fuel System for procedures.
(2) Careful l y remove al l vapor/vacuum l i nes at
EVAP cani ster purge sol enoi d.
(3) Remove EVAP cani ster purge sol enoi d.
(4) Di sconnect el ectri cal connector at LDP.
(5) Careful l y remove vapor/vacuum l i nes at LDP.
(6) Remove LDP mounti ng nuts/bol ts.
(7) Remove LDP from vehi cl e.
(8) Reverse the removal procedures for i nstal l a-
ti on. The vapor/vacuum l i nes must be fi rml y con-
nected. Check the vapor/vacuum l i nes at both the
LDP and EVAP cani ster sol enoi d for damage or
Fig. 17 EVAP Canister Purge SolenoidTypical
WINDSHIELD WASHER RES- ERVOIR BOTTLE LEFT FRONT FENDER ELECTRICAL CONNECTOR BRACKET MOUNTING NUTS (2) DUTY CYCLE EVAP CANISTER PURGE SOLENOID
Fig. 18 Leak Detection Pump (LDP) Location
DUTY CYCLE EVAP CANISTER PURGE SOLENOID LEFT FRONT FENDER LEAK DETECTION PUMP (LDP) TEST PORT TO EVAP CANISTER LEAK DETECTION PUMP (LDP) VACUUM LINES LDP FILTER FWD
ZG EMISSION CONTROL SYSTEMS 25 - 19
REMOVAL AND INSTALLATION (Continued)
l eaks. I f a l eak i s present, a Di agnosti c Troubl e Code
(DTC) may be set.
SPECIFICATIONS
TORQUE CHART
Description Torque
EVAP Cani ster Mounti ng Nuts . . 9 Nm (80 i n. l bs.)
EVAP Cani ster Purge Sol enoi d
Mounti ng Nuts . . . . . . . . . . . . 5 Nm (45 i n. l bs.)
LDP Pump Bracket Nuts . . . . . . . 7 Nm (60 i n. l bs.)
25 - 20 EMISSION CONTROL SYSTEMS ZG
REMOVAL AND INSTALLATION (Continued)
EMISSION CONTROL SYSTEM
CONTENTS
page page
EXHAUST EMISSION CONTROLS2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ON-BOARD DIAGNOSTICS2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ON-BOARD DIAGNOSTICS2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
SYSTEM DESCRIPTION2.5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . 2
GENERAL INFORMATION
SYSTEM DESCRIPTION2. 5L DIESEL ENGINE
The 2.5L di esel MSA control l er and Powertrai n
Control Modul e (PCM) moni tor and control many di f-
ferent ci rcui ts i n the fuel i njecti on pump and engi ne
systems. I f the MSA senses a probl em wi th a moni -
tored ci rcui t that i ndi cates an actual probl em, a
Di agnosti c Troubl e Code (DTC) wi l l be stored i n the
PCMs memory, and eventual l y may i l l umi nate the
Di esel Gl ow Pl ug l amp constantl y whi l e the key i s
on. I f the probl em i s repai red, or i s i ntermi ttent, the
PCM wi l l erase the DTC after 40 warm-up cycl es. A
warm-up cycl e consi sts of starti ng the vehi cl e when
the engi ne i s col d, then the engi ne to warms up to a
certai n temperature, and fi nal l y, the engi ne tempera-
ture fal l s to a normal operati ng temperature, then
the key i s turned off.
Certai n cri teri a must be met for a DTC to be
entered i nto PCM memory. The cri teri a may be a
speci fi c range of engi ne rpm, engi ne or fuel tempera-
ture and/or i nput vol tage to the PCM. A DTC i ndi -
cates that the PCM has i denti fi ed an abnormal
si gnal i n a ci rcui t or the system. A DTC may i ndi cate
the resul t of a fai l ure, but never i denti fy the fai l ed
component di rectl y.
There are several operati ng condi ti ons that the
MSA does not moni tor and set a DTC for. Refer to
the fol l owi ng Moni tored Ci rcui ts and NonMoni tored
Ci rcui ts i n thi s secti on.
MONITORED CIRCUITS
The MSA can detect certai n probl ems i n the el ec-
tri cal system.
Open or Shorted Circuit The MSA can deter-
mi ne i f sensor output (whi ch i s the i nput to MSA i s
wi thi n proper range. I t al so determi nes i f the ci rcui t
i s open or shorted.
Output Device Current Flow The MSA senses
whether the output devi ces are el ectri cal l y connected.
I f there i s a probl em wi th the ci rcui t, the MSA
senses whether the ci rcui t i s open, shorted to ground
(), or shorted to (+) vol tage.
NONMONITORED CIRCUITS
The MSA does not moni tor the fol l owi ng ci rcui ts,
systems or condi ti ons that coul d have mal functi ons
that resul t i n dri veabi l i ty probl ems. A DTC wi l l not
be di spl ayed for these condi ti ons.
Fuel Pressure: Fuel pressure i s control l ed by the
fuel i njecti on pump. The PCM cannot detect prob-
l ems i n thi s component.
Cylinder Compression: The MSA cannot detect
uneven, l ow, or hi gh engi ne cyl i nder compressi on.
Exhaust System: The MSA cannot detect a
pl ugged, restri cted or l eaki ng exhaust system.
Fuel Injector Malfunctions: The MSA cannot
determi ne i f the fuel i njector i s cl ogged, or the wrong
i njector i s i nstal l ed. The fuel i njectors on the di esel
engi ne are not controlled by the MSA, al though a
defecti ve fuel i njector sensor is monitored by the
PCM.
ZG EMISSION CONTROL SYSTEM 25 - 1
Vacuum Assist: Leaks or restri cti ons i n the vac-
uum ci rcui ts of vacuum assi sted engi ne control sys-
tem devi ces are not moni tored by the MSA.
MSA System Ground: The MSA cannot deter-
mi ne a poor system ground. However, a DTC may be
generated as a resul t of thi s condi ti on.
MSA/PCM Connector Engagement: The MSA
cannot determi ne spread or damaged connector pi ns.
However, a DTC may be generated as a resul t of thi s
condi ti on.
HIGH AND LOW LIMITS
The MSA compares i nput si gnal vol tages from each
i nput devi ce. I t wi l l establ i sh hi gh and l ow l i mi ts
that are programmed i nto i t for that devi ce. I f the
i nput vol tage i s not wi thi n speci fi cati ons and other
DTC cri teri a are met, a DTC wi l l be stored i n mem-
ory. Other DTC cri teri a mi ght i ncl ude engi ne rpm
l i mi ts or i nput vol tages from other sensors or
swi tches. The other i nputs mi ght have to be sensed
by the MSA when i t senses a hi gh or l ow i nput vol t-
age from the control system devi ce i n questi on.
DESCRIPTION AND OPERATION
DIAGNOSTIC TROUBLE CODES
On the fol l owi ng pages, a l i st of DTCs i s provi ded
for the 2.5L di esel engi ne. A DTC i ndi cates that the
PCM has recogni zed an abnormal si gnal i n a ci rcui t
or the system. A DTC may i ndi cate the resul t of a
fai l ure, but most l i kel y wi l l not i denti fy the fai l ed
component di rectl y.
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored DTC can be di spl ayed through the use of
the DRB I I I scan tool . The DRB I I I connects to the
data l i nk connector. The data l i nk connector i s
l ocated under the i nstrument panel near bottom of
the steeri ng col umn (Fi g. 1).
ERASING TROUBLE CODES
After the probl em has been repai red, use the DRB
I I I scan tool to erase a DTC.
Fig. 1 Data Link Connector LocationTypical
25 - 2 EMISSION CONTROL SYSTEM ZG
GENERAL INFORMATION (Continued)
MSA CONTROLLER DRBIII CODES
Generic Scan Tool Code DRB III Scan Tool Display
P0100 Mass of Volumes of Air Flow Plausibility
Mass of Volumes of Air Flow Signal High Exceeded
Mass of Volumes of Air Flow Signal Low Exceeded
P0115 Temperature of Engine Coolant SRC High Exceeded
Temperature of Engine Coolant SRC Low Exceeded
P0180 Fuel Temperature Sensor SRC High Exceeded
Fuel Temperature Sensor SRC Low Exceeded
P0400 EGR Open Circuit
EGR Short Circuit
P0500 Vehicle Speed Sensor PEC Frequency Too High
Vehicle Speed Sensor Signal High Exceeded
Vehcle Speed Sensor Plausibility
P0725 Engine Speed Sensor Dynamic Plausibility
Engine Speed Sensor Over Speed Recognition
Engine Speed Sensor Static Plausibilty
P1105 Atmospheric Pressure Sensor SRC High Exceeded
Atmospheric Pressure Sensor SRC Low Exceeded
P1201 Needle Movement Sensor High Exceeded
Needle Movement Sensor Low Exceeded
P1220 Fuel Quantity Actuator Neg. Gov. Deviation Cold
Fuel Quantity Actuator Neg. Gov. Deviation Warm
Fuel Quantity Actuator Pos. Gov. Deviation Cold
Fuel Quantity Actuator Pos. Gov. Deviation Warm
P1225 Control Sleeve Sensor Signal High Exceeded
Control Sleeve Sensor Start End Pos. Not Attained
Control Sleeve Sensor Stop End Pos. Not Attained
P1230 Timing Control Negative Governing Governor Deviation
Timing Control Positive Governing Governor Deviation
P1515 Accelerator Pedal Postion Sensor Signal High Exceeded
Accelerator Pedal Sensor Signal Low Exceeded
Accelerator Pedal Sensor Signal PWG Plaus With Low Idle Switch
Accelerator Pedal Sensor Signal PWG Plaus With Potentiometer
P1600 Battery Voltage SRC High Exceeded
P1605 Terminal #15 Plausibility After Startup
P1610 Regulator Lower Regulator Limit
Regulator Upper Regulator Limit
P1615 Microcontroller Gate-Array Monitoring
Microcontroller Gate-Array Watchdog
Microcontroller Prepare Fuel Quantity Stop
Microcontroller Recovery Was Occurred
Microcontrller Redundant Overrun Monitoring
P1630 Solenoid Valve Controller Open Circuit
Solenoid Valve Controller Short Circuit
ZG EMISSION CONTROL SYSTEM 25 - 3
DESCRIPTION AND OPERATION (Continued)
Generic Scan Tool Code DRB III Scan Tool Display
P1635 Glow Relay Controller Open Circuit
Glow Relay Controller Short Circuit
P1650 Diagnostic Lamp Open Circuit
Diagnostic Lamp Short Circuit
P1660 Redundant Emer. Stop Plausibility In After-Run
Redundant Emer Stop Powerstage Defective
P1665 Cruise Status Indicator Lamp Short Circuit
P1680 EEPROM Plausibility Checksum Error for Adj.
EEPROM Plausibility Checksum Error in CC212
EEPROM Plausibility Communication With EEPROM
EEPROM Plausibility Func. Switch Wrong or Missing
EEPROM Plausibility Ver Number Not Corresponding
P1685 Vehicle Theft Alarm Code Line Breakdown
P1703 Brake Signal Plaus With Redundant Contact
P1740 Clutch Signal Plausibilty
P1725 Inductive Aux. Speed Sensor Dynamic Plausibilty
Inductive Aux. Speed Sensor Overspeed Recognition
Inductive Aux Speed Sensor Plausibilty
Inductive Aux. Speed Sensor Static Plausibilty
PCM DRBIII CODES
Generic Scan Tool Code DRBIII Scan Tool Display
P0117 Engine Coolant Volts Lo
P0118 Engine Coolant Volts Hi
P0500 Vehicle Speed Signal
P0601 Internal Self Test
P1296 5 VDC Output
P1391 Loss of Cam or Crank
25 - 4 EMISSION CONTROL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
EXHAUST EMISSION CONTROLS2.5L DIESEL ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VACUUM HOSE ROUTING SCHEMATIC . . . . . . 5
DIAGNOSIS AND TESTING
EGR GAS FLOW TEST . . . . . . . . . . . . . . . . . . . 6
ELECTRIC VACUUM MODULATOR (EVM) TEST . . 6
REMOVAL AND INSTALLATION
EGR TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRIC VACUUM MODULATOR (EVM) . . . . . 7
SPECIFICATIONS
TORQUE CHART2.5L DIESEL . . . . . . . . . . . . 8
DESCRIPTION AND OPERATION
VACUUM HOSE ROUTING SCHEMATIC
Vacuum for the EGR system i s suppl i ed by the
i nternal engi ne mounted vacuum pump. Refer to
EGR System Operati on for vacuum pump i nforma-
ti on. Vacuum harness routi ng for emi ssi on rel ated
components i s di spl ayed i n (Fi g. 1).
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION
The EGR system reduces oxi des of ni trogen (NOx)
i n the engi ne exhaust. Thi s i s accompl i shed by al l ow-
i ng a predetermi ned amount of hot exhaust gas to
reci rcul ate and di l ute the i ncomi ng fuel /ai r mi xture.
A mal functi oni ng EGR system can cause engi ne
stumbl e, sags or hesi tati on, rough i dl e, engi ne stal l -
i ng and poor dri veabi l i ty.
EGR SYSTEM OPERATION
The system consi sts of:
An EGR val ve assembl y. The val ve i s l ocated
behi nd the i ntake mani fol d (Fi g. 2).
An El ectri c Vacuum Modul ator (EVM). The EVM
i s someti mes referred to as the EGR control sol enoi d
or EGR duty cycl e sol enoi d. The EVM serves two di f-
ferent functi ons. One i s to control vacuum bl eedoff
of the EGR val ve. The other i s to control the on
ti me of the EGR val ve.
The MSA operates the EVM. The MSA i s l ocated
i s l ocated i nsi de the vehi cl e i n the center consul e.
An EGR tube (Fi g. 2) connecti ng a passage i n
the EGR val ve to the rear of the exhaust mani fol d.
Fig. 1 Typical Hose Routing
Fig. 2 EGR Valve and Tube Location
ZG EMISSION CONTROL SYSTEM 25 - 5
The vacuum pump suppl i es vacuum for the
EVM and the EGR val ve. Thi s pump al so suppl i es
vacuum for operati on of the power brake booster. The
pump i s l ocated i nternal l y i n the front of the engi ne
bl ock (Fi g. 3) and i s dri ven by the crankshaft gear.
Vacuum l i nes and hoses to connect the vari ous
components.
When the MSA suppl i es a vari abl e ground si gnal
to the EVM, EGR system operati on starts to occur.
The MSA wi l l moni tor and determi ne when to suppl y
and remove thi s vari abl e ground si gnal . Thi s wi l l
depend on i nputs from the engi ne cool ant tempera-
ture, throttl e posi ti on and engi ne speed sensors.
When the vari abl e ground si gnal i s suppl i ed to the
EVM, vacuum from the vacuum pump wi l l be
al l owed to pass through the EVM and on to the EGR
val ve wi th a connecti ng hose.
Exhaust gas reci rcul ati on wi l l begi n i n thi s order
when:
The MSA determi nes that EGR system operati on
i s necessary.
The engi ne i s runni ng to operate the vacuum
pump.
A vari abl e ground si gnal i s suppl i ed to the EVM.
Vari abl e vacuum passes through the EVM to the
EGR val ve.
The i nl et seat (poppet val ve) at the bottom of
the EGR val ve opens to di l ute and reci rcul ate
exhaust gas back i nto the i ntake mani fol d.
The EGR system wi l l be shut down by the MSA
after 60 seconds of conti nuous engi ne i dl i ng to
i mprove i dl e qual i ty.
DIAGNOSIS AND TESTING
EGR GAS FLOW TEST
Use the fol l owi ng test procedure to determi ne i f
exhaust gas i s fl owi ng through the EGR val ve. I t can
al so be used to determi ne i f the EGR tube i s pl ugged,
or the system passages i n the i ntake or exhaust man-
i fol ds are pl ugged.
Thi s i s not to be used as a compl ete test of the
EGR system.
The engi ne must be started, runni ng and warmed
to operati ng temperature for thi s test.
(1) Al l EGR val ves are equi pped wi th a vacuum
suppl y fi tti ng l ocated on the EGR val ve vacuum
motor (Fi g. 2).
(2) Di sconnect the rubber hose from the vacuum
suppl y fi tti ng (Fi g. 2).
(3) Connect a handhel d vacuum pump to thi s fi t-
ti ng.
(4) Start the engi ne.
(5) Sl owl y appl y 10 i nches of vacuum to the fi tti ng
on the EGR val ve motor. Vacuum shoul d hol d steady
at 10 i nches. I f not, repl ace the EGR val ve. I f vac-
uum hol ds steady at 10 i nches, proceed to next step.
(6) Whi l e appl yi ng vacuum, and wi th the engi ne
runni ng at i dl e speed, the i dl e speed shoul d drop, a
rough i dl e may occur, or the engi ne may even stal l .
Thi s i s i ndi cati ng that exhaust gas i s fl owi ng through
the EGR tube between the i ntake and exhaust man-
i fol ds.
(7) I f the engi ne speed di d not change, the EGR
val ve may be defecti ve, the EGR tube may be
pl ugged wi th carbon, or the passages i n the i ntake
and exhaust mani fol ds may be pl ugged wi th carbon.
(a) Remove EGR val ve from engi ne. Refer to
EGR Val ve Removal i n thi s group.
(b) Appl y vacuum to the vacuum motor fi tti ng
and observe the stem on the EGR val ve. I f the
stem i s movi ng, i t can be assumed that the EGR
val ve i s functi oni ng correctl y. The probl em i s i n
ei ther a pl ugged EGR tube or pl ugged passages at
the i ntake or exhaust mani fol ds. Refer to step (c).
I f the stem wi l l not move, repl ace the EGR val ve.
(c) Remove the EGR tube between the i ntake
and exhaust mani fol ds. Check and cl ean the EGR
tube and i ts rel ated openi ngs on the mani fol ds.
Refer to EGR Tube i n thi s group for procedures.
Do not attempt to cl ean the EGR val ve. I f the
val ve shows evi dence of heavy carbon bui l dup near
the base, repl ace i t.
ELECTRIC VACUUM MODULATOR (EVM) TEST
VACUUM TEST
Wi th the engi ne runni ng, di sconnect the vacuum
suppl y l i ne at the fi tti ng on the EVM. Mi ni mum vac-
uum shoul d be no l ess than 20 i nches. I f vacuum i s
l ower, check for l eaks i n vacuum suppl y l i ne. I f l eaks
cannot be found, check for l ow vacuum at vacuum
pump. Refer to Group 5, Brake System for proce-
dures.
Fig. 3 Internal Vacuum Pump
25 - 6 EMISSION CONTROL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
REMOVAL AND INSTALLATION
EGR VALVE
REMOVAL
(1) Remove the rubber hose from turbocharger to
metal tube.
(2) Di sconnect vacuum l i ne at EGR val ve vacuum
suppl y fi tti ng (Fi g. 2).
(3) Loosen the tube fi tti ng at exhaust mani fol d end
of EGR tube (Fi g. 2).
(4) Remove the two bol ts retai ni ng the EGR tube
to the si de of EGR val ve (Fi g. 2).
(5) Remove the two EGR val ve mounti ng bol ts
(Fi g. 2) and remove EGR val ve.
(6) Di scard both of the ol d EGR mounti ng gaskets.
INSTALLATION
(1) Cl ean the i ntake mani fol d of any ol d gasket
materi al .
(2) Cl ean the end of EGR tube of any ol d gasket
materi al .
(3) Posi ti on the EGR val ve and new gasket to the
i ntake mani fol d.
(4) I nstal l two EGR val ve mounti ng bol ts. Do not
ti ghten bol ts at thi s ti me.
(5) Posi ti on new gasket between EGR val ve and
EGR tube.
(6) I nstal l two EGR tube bol ts. Ti ghten al l four
mounti ng bol ts to 23 Nm (204 i n. l bs.).
(7) Ti ghten EGR tube fi tti ng at exhaust mani fol d.
(8) Connect vacuum l i ne to EGR val ve.
(9) I nstal l the rubber hose from turbocharger to
metal tube.
EGR TUBE
The EGR tube connects the EGR val ve to the rear
of the exhaust mani fol d (Fi g. 2).
REMOVAL
(1) Remove rubber hose from turbocharger to
metal tube.
(2) Remove two EGR tube mounti ng bol ts at EGR
val ve end of tube (Fi g. 2).
(3) Loosen fi tti ng at exhaust mani fol d end of tube
(Fi g. 2).
(4) Remove EGR tube and di scard ol d gasket.
(5) Cl ean gasket mati ng surfaces and EGR tube
fl ange gasket surfaces.
(6) Check for si gns of l eakage or cracked surfaces
at both ends of tube, exhaust mani fol d and EGR
val ve.
INSTALLATION
(1) I nstal l a new gasket to EGR val ve end of EGR
tube.
(2) Posi ti on EGR tube to engi ne.
(3) Loosel y ti ghten fi tti ng at exhaust mani fol d end
of tube.
(4) I nstal l 2 mounti ng bol ts at EGR val ve end of
tube. Ti ghten bol ts to 23 Nm (204 i n. l bs.) torque.
(5) Ti ghten fi tti ng at exhaust mani fol d end of tube.
(6) I nstal l hose from turbocharger to metal tube.
ELECTRIC VACUUM MODULATOR (EVM)
The EVM (EGR Duty Cycl e Purge Sol enoi d) i s
mounted to the si de of the PDC.
REMOVAL
(1) Di sconnect both cabl es from battery, negati ve
cabl e fi rst.
(2) Remove 2 screws hol di ng PDC to bracket,
swi ng out of way.
(3) Remove nut and cl amp hol di ng battery to bat-
tery tray (Fi g. 4).
(4) Remove battery from vehi cl e.
(5) Di sconnect two vacuum hoses at EVM.
(6) Remove mounti ng screws of EVM.
(7) Remove the EVM to gai n access to the EVM
el ectri cal connector.
(8) Remove el ectri cal connector at EVM.
INSTALLATION
(1) I nstal l el ectri cal connector to EVM.
(2) I nstal l EVM and ti ghten mounti ng screws.
(3) Connect vacuum hoses.
(4) I nstal l PDC to bracket and ti ghten mounti ng
screws.
(5) I nstal l battery.
(6) Connect battery cabl es posi ti ve fi rst.
Fig. 4 Battery Clamp
ZG EMISSION CONTROL SYSTEM 25 - 7
SPECIFICATIONS
TORQUE CHART2. 5L DIESEL
Description Torque
EGR Val ve Mounti ng Bol ts . . . 23 Nm (204 i n. l bs.)
EGR Tube Mounti ng Bol ts . . . . 23 Nm (204 i n. l bs.)
EVM (El ectri c Vacuum Modul ator)
Mounti ng Bol t . . . . . . . . . . . . . 2 Nm (20 i n. l bs.)
25 - 8 EMISSION CONTROL SYSTEM ZG