1997 JEEP GRAND CHEROKEE SERVICE MANUAL

Welcome to the
1997 J eep Grand Cherokee

(RHD&LHD)
Interactive Electronic Service Manual!
CLICK ON VEHICLE TOBEGIN
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GROUP TAB LOCATOR
Introduction
0
Lubrication and Maintenance
2
Suspension
3
Differential and Driveline
5
Brakes
7
Cooling System
8A
Battery
8B
Starter
8C
Charging System
8D
Ignition System
8E
Instrument Panel and Systems
8F
Audio Systems
8G
Horns
8H
Vehicle Speed Control System
8J
Turn Signal and Flashers
8K
Windshield Wipers and Washers
8L
Lamps
8M
Restraint System
8N
Electrically Heated Systems
8P
Power Door Locks
8Q
Vehicle Theft Security System
8R
Power Seats
8S
Power Windows
8T
Power Mirrors
8U
Chime Warning/Reminder System
8V
Overhead Console
8W
Wiring Diagrams
9
Engine
11
Exhaust System and Intake Manifold
13
Bumpers and Frame
14
Fuel System
19
Steering
21
Transaxle
22
Tires and Wheels
23
Body
24
Heating and Air Conditioning
25
Emission Control Systems
INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . 2
FASTENER IDENTIFICATION . . . . . . . . . . . . . . . 3
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . . . . 3
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 6
TORQUE REFERENCES . . . . . . . . . . . . . . . . . . 6
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . 2
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . 2
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
attached to the top l eft si de of the i nstrument panel .
The VI N contai ns 17 characters that provi de data
concerni ng the vehi cl e. Refer to the decodi ng chart to
determi ne the i denti fi cati on of a vehi cl e. The Vehi cl e
I denti fi cati on Number i s al so i mpri nted on the:
Body Code Pl ate.
Equi pment I denti fi cati on Pl ate.
Vehi cl e Safety Certi fi cati on Label .
Frame rai l .
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line X = Grand Cherokee 4X2 (LHD)
Z = Grand Cherokee 4X4 (LHD)
6 Series 5 = Laredo
7 = Limited
7 Body Style 8 = 4dr Sport Utility
8 Engine S = 4.0 Liter
Y = 5.2 Liter
Z = 5.9 Liter
9 Check Digit
10 Model Year V = 1997
11 Assembly Plant C = Jefferson Assembly
12 thru 17 Vehicle Build Sequence
ZG INTRODUCTION 1
VEHICLE SAFETY CERTIFICATION LABEL
A vehi cl e safety certi fi cati on l abel (Fi g. 1) i s
attached to every Chrysl er Corporati on vehi cl e. The
l abel certi fi es that the vehi cl e conforms to al l appl i -
cabl e Federal Motor Vehi cl e Safety Standards. The
l abel al so l i sts:
Month and year of vehi cl e manufacture.
Gross Vehi cl e Wei ght Rati ng (GVWR). The gross
front and rear axl e wei ght rati ngs (GAWRs) are
based on a mi ni mum ri m si ze and maxi mum col d ti re
i nfl ati on pressure.
Vehi cl e I denti fi cati on Number (VI N).
Type of vehi cl e.
Type of rear wheel s.
Bar code.
Month, Day and Hour (MDH) of fi nal assembl y.
Pai nt and Tri m codes.
Country of ori gi n.
The l abel i s l ocated on the dri ver-si de door shut-
face.
BODY CODE PLATE
A metal Body Code pl ate i s attached to the top, l eft
si de of the radi ator rei nforcement. The i nformati on
l i sted on the pl ate (Fi g. 2) i s used for manufacturi ng
and servi ce purposes.
VEHICLE DIMENSIONS
The Vehi cl e Di mensi ons chart provi des the di men-
si ons for each type of Grand Cherokee vehi cl e.
Fig. 1 Vehicle Safety CertificationLabelTypical
Fig. 2 Body Code Plate
EXTERIOR DIMENSIONS
WHEELBASE
cm/in
TRACK
FRONT-REAR
cm/in
LENGTH OVERALL
WIDTH
cm/in
HEIGHT
269.1
105.9
147.3 147.3
58.0 58.0
448.8
176.7
176.0
69.3
164.3
64.7
INTERIOR DIMENSIONS
HEAD
FRONT-REAR
cm/in
LEG
FRONT-REAR
cm/in
SHOULDER
FRONT-REAR
cm/in
HIP
FRONT-REAR
cm/in
98.8 99.0
38.9 39.0
103.8 90.6
40.9 35.7
148.0 146.3
58.3 57.6
146.8 125.2
57.8 49.3
2 INTRODUCTION ZG
GENERAL INFORMATION (Continued)
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS
The graphi c symbol s i l l ustrated i n the fol l owi ng
chart (Fi g. 3) are used to i denti fy vari ous i nstrument
control s. The symbol s correspond to the control s and
di spl ays that are l ocated on the i nstrument panel .
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
SAE and metri c bol t/nut threads are not the same.
The di fference i s descri bed i n the Thread Notati on
chart (Fi g. 4).
GRADE/CLASS IDENTIFICATION
The SAE bol t strength grades range from grade 2
to grade 8. The hi gher the grade number, the greater
the bol t strength. I denti fi cati on i s determi ned by the
l i ne marks on the top of each bol t head. The actual
bol t strength grade corresponds to the number of l i ne
marks pl us 2. The most commonl y used metri c bol t
strength cl asses are 9.8 and 12.9. The metri c
strength cl ass i denti fi cati on number i s i mpri nted on
the head of the bol t. The hi gher the cl ass number,
the greater the bol t strength. Some metri c nuts are
i mpri nted wi th a si ngl e-di gi t strength cl ass on the
nut face. Refer to the Fastener I denti fi cati on and
Fastener Strength Charts.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
HIGH BEAM FOG LIGHTS HEADLIGHTS, PARKING LIGHTS, PANEL LIGHTS TURN SIGNAL HAZARD WARNING WINDSHIELD WASHER WINDSHIELD WIPER WINDSHIELD WIPER AND WASHER WINDSCREEN DEMISTING AND DEFROSTING VENTILATING FAN REAR WINDOW DEFOGGER REAR WINDOW WIPER REAR WINDOW WASHER FUEL ENGINE COOLANT TEMPER- ATURE BATTERY CHARGING CON- DITION ENGINE OIL SEAT BELT BRAKE FAILURE PARKING BRAKE FRONT HOOD REAR HOOD (TRUNK) HORN LIGHTER
Fig. 3
Fig. 4 Thread NotationSAE and Metric
ZG INTRODUCTION 3
4 INTRODUCTION ZG
FASTENER STRENGTH
HOW TO DETERMINE BOLT STRENGTH Mark Class Mark Class Hexagon head bolt Bolt head No. Stud bolt No mark No mark Hexagon flange bolt w/washer hexagon bolt No mark Grooved Hexagon head bolt Two protruding lines Hexagon flange bolt w/washer hexagon bolt Two protruding lines Welded bolt Hexagon head bolt Three protruding lines Hexagon head bolt Four protruding lines
ZG INTRODUCTION 5
METRIC SYSTEM
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fi gure art, speci fi cati ons and torque references i n
thi s Servi ce Manual are i denti fi ed i n metri c and SAE
format.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage metri c fasteners (nuts, bol ts,
etc.) for reassembl y. I f the fastener i s not sal vage-
abl e, a fastener of equi val ent speci fi cati on shoul d be
used.
The metri c system i s based on quanti ti es of one,
ten, one hundred, one thousand and one mi l l i on (Fi g.
5).
The fol l owi ng chart wi l l assi st i n converti ng metri c
uni ts to equi val ent Engl i sh and SAE uni ts, or vi se
versa.
Refer to the Conversi on Chart to convert torque
val ues l i sted i n metri c Newton- meters (Nm). Al so,
use the chart to convert between mi l l i meters (mm)
and i nches (i n.)
TORQUE REFERENCES
I ndi vi dual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Speci fi -
cati ons Chart for torque references not l i sted i n the
i ndi vi dual torque charts.
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply By To Get Multiply By To Get
in-lbs x 0.11298 = Newton-Meters (Nm) Nm x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton-Meters (Nm) Nm x 0.7376 = ft-lbs
Inches Hg (60F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters (M) M x 1.0936 = Yards
Miles x 1.6093 = Kilometers (Km) Km x 0.6214 = Miles
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec. x 0.3048 = Meters/Sec. (M/S) M/S x 3.281 = Feet/Sec.
Kilometers/Hr. x 0.27778 = Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 = mph
COMMON METRIC EQUIVALENTS
1 Inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Multiply By To Get Multiply By To Get in-lbs. ft.-lbs. = Newton-Meters (Nm) = Newton-Meters (Nm) Nm Nm = in-lbs. = ft.-lbs. Inches Hg (60F) psi = Kilopascals (kPa) = Kilopascals (kPa) kPa kPa = Inches Hg = psi Inches Feet Yards Miles = Millimeters (mm) = Meters (M) = Meters (M) = Kilometers (Km) mmMM Km = Inches = Feet = Yards = Miles mph Feet/Sec. Kilometers/Hr. mph = Kilometers/Hr. (Km/h) = Meters/Sec. (M/S) = Meters/Sec. (M/S) = Meters/Sec. (M/S) Km/h M/S M/S M/S = mph = Feet/Sec. = Kilometers/Hr. = mph COMMON METRIC EQUIVA- LENTS 1 Inch = 25 Millimeters 1 Foot = 0.3 Meter 1 Yard = 0.9 Meter 1 Mile = 1.6 Kilometers 1 Cubic Inch = 16 Cubic Cen- timeters 1 Cubic Foot = 0.03 Cubic Meter 1 Cubic Yard = 0.8 Cubic Meter
Fig. 5 Metric Prefixes
6 INTRODUCTION ZG
METRIC CONVERSION
ZG INTRODUCTION 7
TORQUE SPECIFICATIONS
SPECIFIED TORQUE FOR STANDARD BOLTS Class Diameter mm Pitch mm Specified torque Hexagon head bolt Hexagon flange bolt Nm kgf-cm ft.-lbf Nm kgf-cm ft.-lbf 48 in.-lbf 52 in.-lbf 56 in.-lbf 65 in.-lbf 69 in.-lbf 78 in.-lbf
8 INTRODUCTION ZG
INTRODUCTION
CONTENTS
page
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
attached to the top l eft si de of the i nstrument panel .
The VI N contai ns 17 characters that provi de data
concerni ng the vehi cl e. Refer to the decodi ng chart to
determi ne the i denti fi cati on of a vehi cl e. The Vehi cl e
I denti fi cati on Number i s al so i mpri nted on the:
Body Code Pl ate.
Equi pment I denti fi cati on Pl ate.
Vehi cl e Safety Certi fi cati on Label .
Frame rai l .
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating G = 5001-6000 lbs.
5 Vehicle Line X = Grand Cherokee 4X2 (LHD)
Z = Grand Cherokee 4X4 (LHD)/(RHD)
6 Transmission B = 4 Speed Auto
N = 5 Speed Manual
7 Body Style 8 = 4dr Sport Utility
8 Engine M = 2.5 Liter Diesel
S = 4.0 Liter
Y = 5.2 Liter
9 Check Digit
10 Model Year U = 1997
11 Assembly Plant Y = Graz Assembly
12 thru 17 Vehicle Build Sequence
ZG INTRODUCTION 1
LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
JUMP STARTING, HOISTING AND TOWING . . . 8
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 2
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Servi ce and mai ntenance procedures for compo-
nents and systems l i sted i n Schedul eA or B can be
found by usi ng the Group Tab Locator i ndex at the
front of thi s manual . I f i t i s not cl ear whi ch group
contai ns the i nformati on needed, refer to the i ndex at
the back of thi s manual .
There are two mai ntenance schedul es that show
proper servi ce based on the condi ti ons that the vehi -
cl e i s subjected to.
Schedul e A , l i sts schedul ed mai ntenance to be
performed when the vehi cl e i s used for general trans-
portati on.
Schedul e B , l i sts mai ntenance i nterval s for vehi -
cl es that are operated under the condi ti ons l i sted at
the begi nni ng of the Mai ntenance Schedul e secti on.
Use the schedul e that best descri bes your dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
PARTS AND LUBRICANT RECOMMENDATIONS
When servi ce i s requi red, Chrysl er Corporati on
recommends that onl y Mopar brand parts, l ubri -
cants and chemi cal s be used. Mopar provi des the
best engi neered products for servi ci ng Chrysl er Cor-
porati on vehi cl es.
INTERNATIONAL SYMBOLS
Chrysl er Corporati on uses i nternati onal symbol s to
i denti fy engi ne compartment l ubri cant and fl ui d
i nspecti on and fi l l l ocati ons (Fi g. 1).
CLASSIFICATION OF LUBRICANTS
Onl y l ubri cants that are endorsed by the fol l owi ng
organi zati on shoul d be used to servi ce a Chrysl er
Corporati on vehi cl e.
Soci ety of Automoti ve Engi neers (SAE)
Ameri can Petrol eum I nsti tute (API ) (Fi g. 2)
Nati onal Lubri cati ng Grease I nsti tute (NLGI )
(Fi g. 3)
Fig. 1 International Symbols
ENGINE OIL AUTOMATIC TRANSMISSION FLUID ENGINE COOLANT BRAKE FLUID POWER STEERING FLUID WINDSHIELD WASHER FLUID
ZG LUBRICATION AND MAINTENANCE 0 - 1
ENGINE OIL
SAE GRADE RATING INDICATES ENGINE OIL 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.
SAE 30 = si ngl e grade engi ne oi l .
SAE 10W-30 = mul ti pl e grade engi ne oi l .
API QUALITY CLASSIFICATION
The API Servi ce Grade speci fi es the type of perfor-
mance the engi ne oi l i s i ntended to provi de. The API
Servi ce Grade speci fi cati ons al so appl y to energy con-
servi ng engi ne oi l s.
Use engi ne oi l s that are API Servi ce Certi fi ed.
5W-30 and 10W-30 MOPAR engi ne oi l s conform to
speci fi cati ons.
Refer to Group 9, Engi ne for engi ne oi l speci fi ca-
ti on.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti pl e grade gear
l ubri cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
G. Chassi s l ubri cant i s i denti fi ed by the l atter L.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
FLUID CAPACITIES
FUEL TANK
Al l . . . . . . . . . . . . . . . . . . . . . . . . . . 87.4 L (23 gal .)
ENGINE OIL W/FILTER CHANGE
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qts.)
5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 L (5.0 qts.)
5.9L . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 L (5.0 qts.)
COOLING SYSTEM
4.0L . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (12.0 qts.)*
5.2L . . . . . . . . . . . . . . . . . . . . . . . 14.1 L (14.9 qts.)*
5.9L . . . . . . . . . . . . . . . . . . . . . . . 14.1 L (14.9 qts.)*
*I ncl udes 2.2 L (2.3 qts.) for cool ant recovery bottl e.
AUTOMATIC TRANSMISSION
Dry fi l l capaci ty. *
42RE . . . . . . . . . . . . . . . . . . . 8.0-10.4 L (17-22 pts.)
44RE . . . . . . . . . . . . . . . . . . . 8.0-10.4 L (17-22 pts.)
* Dependi ng on type and si ze of i nternal cool er,
l ength and i nsi de di ameter of cool er l i nes, or use of an
auxi l i ary cool er, these fi gures may vary. Refer to Group
21, Transmi ssi on for proper fl ui d fi l l procedure.
TRANSFER CASE
242 NVG . . . . . . . . . . . . . . . . . . . . . . 1.4 L (3.0 pts.)
249 NVG . . . . . . . . . . . . . . . . . . . . . . 1.1 L (2.5 pts.)
FRONT AXLE
Model 181 . . . . . . . . . . . . . . . . . . . . 1.18 L (2.5 pts.)
REAR AXLE
Model 194* . . . . . . . . . . . . . . . . . . . . 1.6 L (3.5 pts.)
Model 216* . . . . . . . . . . . . . . . . . . 2.24 L (4.75 pts.)
* I f the vehi cl e i s equi pped wi th TRAC-LOK,
i ncl ude 0.11 L (0.25 pts.) of fri cti on modi fi er.
NOTE: Vehicles with trailer tow, must use a syn-
thetic lubricant. Refer to Group 3, Differential and
Driveline for service procedures.
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
WHEEL BEARINGS CHASSIS LUBRICA- TION CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION AND MAINTENANCE ZG
MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 3
SCHEDULEA . . . . . . . . . . . . . . . . . . . . . . . . . 3
SCHEDULEB . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNSCHEDULED INSPECTION . . . . . . . . . . . . . . 3
GENERAL INFORMATION
INTRODUCTION
There are two mai ntenance schedul es that show
proper servi ce i nterval s for ZJ vehi cl es. Use the
schedul e that best descri bes the condi ti ons the vehi -
cl e i s operated under. When mi l eage and ti me i s
l i sted, fol l ow the i nterval that occurs fi rst.
Schedule-A l i sts al l the schedul ed mai ntenance to
be performed under normal operati ng condi ti ons.
Schedule-B i s a schedul e for vehi cl es that are
usual l y operated under one or more of the fol l owi ng
condi ti ons:
Frequent short tri ps dri vi ng l ess than 5 mi l es (8
km)
Frequent dri vi ng i n dusty condi ti ons
Extensi ve i dl i ng
Trai l er towi ng
Sustai ned hi gh speed operati on
Off road dri vi ng
Desert operati on
Frequent starti ng and stoppi ng
Col d cl i mate operati on
Commerci al servi ce
EMISSION CONTROL SYSTEM MAINTENANCE
The schedul ed emi ssi on mai ntenance l i sted i n bold
type on the Mai ntenance Schedul es, must be done at
the mi l eage speci fi ed to assure the conti nued proper
functi oni ng of the emi ssi on control system. These,
and al l other mai ntenance servi ces i ncl uded i n thi s
manual , shoul d be done to provi de the best vehi cl e
performance and rel i abi l i ty. More frequent mai nte-
nance may be needed for vehi cl es i n severe operati ng
condi ti ons such as dusty areas and very short tri p
dri vi ng.
UNSCHEDULED INSPECTION
AT EACH STOP FOR FUEL
Check engi ne oi l l evel , add as requi red.
Check wi ndshi el d washer sol vent and add i f
requi red.
ONCE A MONTH
Check ti re pressure and l ook for unusual wear
or damage.
I nspect battery and cl ean and ti ghten termi nal s
as requi red. Check el ectrol yte l evel and add water as
needed.
Check fl ui d l evel s of cool ant reservoi r, power
steeri ng and transmi ssi on and add as needed.
Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
AT EACH OIL CHANGE
I nspect exhaust system.
I nspect brake hoses.
Rotate the ti res at each oi l change i nterval
shown on Schedul eA (7,500 mi l es) or every other
i nterval shown on Schedul eB (6,000 mi l es).
Check cool ant l evel , hoses and cl amps.
Lubri cate suspensi on bal l joi nts.
After compl eti on of off-road (4WD) operati on, the
undersi de of the vehi cl e shoul d be thoroughl y
i nspected. Exami ne threaded fasteners for l ooseness.
SCHEDULEA
7,500 miles (12 000 km) or at 6 months
Change engi ne oi l .
Repl ace engi ne oi l fi l ter.
Lubri cate steeri ng l i nkage (4x4 onl y).
15,000 Miles (24 000 km) or at 12 months
Lubri cate steeri ng l i nkage.
I nspect brake l i ni ngs.
Replace engine air cleaner element.
Replace spark plugs.
I nspect dri ve bel t.
Drai n and refi l l automati c transmi ssi on fl ui d.
Drai n and refi l l transfer case fl ui d.
Fl ush and repl ace engi ne cool ant at 36 months,
regardl ess of mi l eage.
Fl ush and repl ace engi ne cool ant i f not done at
36 months.
Replace ignition wires.
Inspect PCV valve and replace if necessary
(5.2L & 5.9L only).*
Repl ace fuel fi l ter.**
*Thi s mai ntenance i s recommended, but i s not
requi red to mai ntai n warranty on the PCV val ve.
**Recommended for proper vehi cl e performance for
vehi cl es bui l t for sal e i n Cal i forni a.
Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
change.
change.
change.
(5.2L & 5.9L only).*
IMPORTANT: I nspecti on and servi ce shoul d al so
be performed anyti me a mal functi on i s observed or
suspected.
SCHEDULEB
3,000 Miles (5 000 km)
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
12,000 Miles (19 000 km)
Drai n and refi l l front and rear axl es.
15,000 miles (24 000 km)
Inspect engine air cleaner element, replace
as necessary.
18,000 Miles (29 000 km)
21,000 Miles (34 000 km)
24,000 Miles (38 000 km)
27,000 Miles (43 000 km)
30,000 Miles (48 000 km)
(5.2L & 5.9L only).*
*Thi s mai ntenance i s recommended to the cus-
tomer, but i s not requi red to mai ntai n warranty on
the PCV val ve.
33,000 Miles (53 000 km)
36,000 Miles (58 000 km)
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
as necessary.
48,000 Miles (77 000 km)
51,000 Miles (82 000 km)
Fl ush and repl ace engi ne cool ant.
54,000 Miles (86 000 km)
57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
(5.2L & 5.9L only).*
Repl ace spark pl ugs.
63,000 Miles (101 000 km)
66,000 Miles (106 000 km)
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
75,000 Miles (120 000 km)
as necessary.
78,000 Miles (125 000 km)
81,000 Miles (130 000 km)
84,000 miles (134 000 km)
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
(5.2L & 5.9L only).*
93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
99,000 Miles (158 000 km)
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
as necessary.
108,000 Miles (173 000 km)
111,000 Miles (178 000 km)
114,000 Miles (182 000 km)
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
(5.2L & 5.9L only).
IMPORTANT: I nspecti on and servi ce shoul d al so
be performed anyti me a mal functi on i s observed or
suspected.
J UMP STARTING, HOISTING AND TOWING
INDEX
page page
SERVICE PROCEDURES
EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . 10
FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . 10
HOISTING RECOMMENDATIONS . . . . . . . . . . 10
JUMP STARTING PROCEDURE . . . . . . . . . . . . . 8
TOWING RECOMMENDATIONS . . . . . . . . . . . . . 9
TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . . 9
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/STARTING/
CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP
START A FROZEN BATTERY, PERSONAL INJURY CAN
RESULT. DO NOT JUMP START WHEN MAINTENANCE
FREE BATTERY INDICATOR DOT IS YELLOW OR
BRIGHT COLOR. DO NOT JUMP START A VEHICLE
WHEN THE BATTERY FLUID IS BELOW THE TOP OF
LEAD PLATES. DO NOT ALLOW JUMPER CABLE
CLAMPS TO TOUCH EACH OTHER WHEN CON-
NECTED TO A BOOSTER SOURCE. DO NOT USE
OPEN FLAME NEAR BATTERY. REMOVE METALLIC
JEWELRY WORN ON HANDS OR WRISTS TO AVOID
INJURY BY ACCIDENTAL ARCING OF BATTERY CUR-
RENT. WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PRO-
VIDED WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO J UMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
Battery cabl e cl amp condi ti on, cl ean i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
Generator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster source,
park the booster vehi cl e wi thi n cabl e reach. Turn off al l
accessori es, set the parki ng brake, pl ace the automati c
transmi ssi on i n PARK or the manual transmi ssi on i n
NEUTRAL and turn the i gni ti on OFF.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake. Turn off al l accesso-
ri es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t.
Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to posi ti ve (+) termi nal . Connect BLACK
jumper cabl e cl amp to engi ne ground as cl ose to the
ground cabl e attachi ng poi nt as possi bl e (Fi g. 1).
(6) Start the engi ne i n the vehi cl e whi ch has the
booster battery, l et the engi ne i dl e a few mi nutes,
then start the engi ne i n the vehi cl e wi th the di s-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
Fig. 1 Jumper Cable Clamp Connections
ENGINE GROUND NEGATIVE JUMPER CABLE BATTERY NEGATIVE CABLE POSITIVE JUMPER CABLE BATTERY POSITIVE CABLE BATTERY TEST INDICATOR
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect BLACK
cabl e cl amp from battery negati ve termi nal . Di sconnect
RED cabl e cl amp from battery posi ti ve termi nal .
Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
TOWING RECOMMENDATIONS
A vehi cl e equi pped wi th SAE approved sl i ng-type
towi ng equi pment or a wheel -l i ft towi ng devi ce can
be used to tow al l ZJ vehi cl es. When towi ng a 4WD
vehi cl e, use tow dol l i es under the opposi te end of the
vehi cl e. A vehi cl e wi th a fl at-bed devi ce can al so be
used to transport a di sabl ed vehi cl e (Fi g. 2).
SAFETY PRECAUTIONS
The fol l owi ng safety precauti ons must be observed
when towi ng a vehi cl e:
Secure l oose and protrudi ng parts.
Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl es fuel tank.
Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
Do not attach tow chai ns, T-hooks, J-hooks, or a
tow sl i ng to a bumper, steeri ng l i nkage, dri ve shafts
or a non-rei nforced frame hol e.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehi cl e shoul d be rai sed unti l l i fted wheel s
are a mi ni mum 100 mm (4 i n) from the ground. Be
sure there i s adequate ground cl earance at the oppo-
si te end of the vehi cl e, especi al l y when towi ng over
rough terrai n or steep ri ses i n the road. I f necessary,
remove the wheel s from the l i fted end of the vehi cl e
and l ower the vehi cl e cl oser to the ground, to
i ncrease the ground cl earance at the opposi te end of
the vehi cl e. I nstal l l ug nuts on wheel attachi ng studs
to retai n brake drums.
FLAT-BED TOWING RAMP ANGLE
I f a vehi cl e wi th fl at-bed towi ng equi pment i s used,
the approach ramp angl e shoul d not exceed 15
degrees.
TWO-WHEEL-DRIVE VEHICLE TOWING
Chrysl er Corporati on recommends that a vehi cl e be
towed wi th the rear end l i fted, whenever possi bl e.
TOWING-REAR END LIFTED
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
Vehi cl es can be towed wi th the front wheel s on the
ground for extended di stances at speeds not exceed-
i ng 48 km/h (30 mph).
(1) Attach the J-hooks around the axl e shaft tube
outboard of the rear spri ngs.
(2) Posi ti on and center the sl i ng under and for-
ward of the rear bumper.
(3) Attach safety chai ns (wi th pads) at each end of
the rear bumper.
(4) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
(5) Secure the steeri ng wheel i n strai ght ahead
posi ti on wi th a cl amp devi ce desi gned for towi ng.
(6) Veri fy that steeri ng components are i n good
condi ti on.
(7) Shi ft the transmi ssi on to NEUTRAL.
TOWING-FRONT END LIFTED
To prevent damage to front faci a components, use
onl y a Wheel -Li ft type towi ng devi ce or Fl at-Bed
haul i ng equi pment.
Fig. 2 Tow Vehicles With Approved Equipment.
SLING TYPE WHEEL LIFT FLAT BED
SERVICE PROCEDURES (Continued)
2WDAUTOMATIC TRANSMISSION
Provi ded the transmi ssi on i s operabl e, tow onl y i n
NEUTRAL at speeds not to exceed 30 mph (50
km/h) and di stances l ess than 15 mi l es (25km/h).
I f the vehi cl e i s to be towed more than 15 mi l es,
the propel l er shaft shoul d be di sconnected or pl ace
tow dol l i es under rear wheel s.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysl er Corporati on recommends that a vehi cl e be
transported on a fl at-bed devi ce. A Wheel -l i ft or
Sl i ng-type devi ce can be used provi ded al l the wheel s
are l i fted off the ground usi ng tow dol l i es.
4WD TOWING-REAR END LIFTED
(1) Rai se the front of the vehi cl e off the ground
and i nstal l tow dol l i es under front wheel s.
(2) Attach the J-hooks around the axl e shaft tube
outboard of the rear spri ngs.
(3) Posi ti on and center the sl i ng under and for-
ward of the rear bumper.
(4) Attach safety chai ns (wi th pads) at each end of
the rear bumper.
(5) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
(6) Secure the steeri ng wheel i n strai ght ahead
posi ti on wi th a cl amp devi ce desi gned for towi ng.
(7) Shi ft the transfer case to NEUTRAL.
4WD TOWING-FRONT END LIFTED
To prevent damage to front faci a components, use
onl y a Wheel -Li ft type towi ng devi ce or Fl at-Bed
haul i ng equi pment.
I f usi ng the wheel -l i ft towi ng method, i nstal l tow
dol l i es under rear wheel s.
EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehi cl es are equi pped wi th front emer-
gency tow hooks. The tow hooks shoul d be used for
EMERGENCY purposes onl y.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
HOISTING RECOMMENDATIONS
FLOOR J ACK
When properl y posi ti oned, a fl oor jack can be used
to l i ft a ZJ vehi cl e (Fi g. 3). Support the vehi cl e i n the
rai sed posi ti on wi th jack stands at the front and rear
ends of the frame rai l s.
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under:
An axle tube.
Aluminum differential.
A body side sill.
A steering linkage component.
A drive shaft.
The engine or transmission oil pan.
The fuel tank.
A front suspension arm.
HOIST
A vehi cl e can be l i fted wi th:
A si ngl e-post, frame-contact hoi st.
A twi n-post, chassi s hoi st.
A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used, ver-
ify that the lifting pads are positioned properly (Fig. 3).
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
Fig. 3 Correct Vehicle Lifting Locations
DRIVE-ON HOIST
FRAME CONTACT HOIST
TWIN POST CHASSIS HOIST
FLOOR JACK
LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INDEX
page page
SPECIFICATIONS
ENGINE OILDIESEL ENGINES . . . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
ENGINE OILDIESEL ENGINES
Use onl y Di esel Engi ne Oi l meeti ng standard MIL-
2104C or API Cl assi fi cati on SG/CD or CCMC PD2.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properl y formul ated engi ne oi l s, i t i s
recommended that SAE Grade 15W-40 engi ne oi l s
that meet Chrysl er materi al standard MS-6395, be
used. European Grade 10W-40 oi l s are al so accept-
abl e.
Oi l s of the SAE 5W-30 or 10W-30 grade number
are preferred when mi ni mum temperatures consi s-
tentl y fal l bel ow -12C.
FLUID CAPACITIES
FUEL TANK
Di esel Engi ne Equi pped Vehi cl es . . . . . . . . . . 87.4 L
ENGINE OIL
2.5L Di esel Engi ne (i ncl udes fi l ter) . . . . . . . . . 6.5 L
COOLING SYSTEM
2.5L Di esel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 L
MANUAL TRANSMISSION
Recommended l ubri cant for AX15 transmi ssi ons i s
Mopar 75W90, API Grade GL3 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.
Approximate dry fill lubricant capacity is:
3.10 l i ters (3.27 qts.) for 4wheel dri ve appl i ca-
ti ons.
3.15 l i ters (3.32 qts.) for 2wheel dri ve appl i ca-
ti ons.
TRANSFER CASE
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 L
FRONT AXLE
Model 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48 L
MAINTENANCE SCHEDULE
INDEX
page page
GENERAL INFORMATION
MAINTENANCE SCHEDULEDIESEL ENGINE . 2
SCHEDULEA . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SCHEDULEB . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
MAINTENANCE SCHEDULEDIESEL ENGINE
The fol l owi ng are engi ne rel ated Mai ntenance
i tems whi ch are uni que to Di esel engi ne-equi pped
vehi cl es. Refer to the 1997 ZJ Servi ce Manual for
gasol i ne engi ne and non-engi ne rel ated Mai ntenance
Schedul es
The servi ce i nterval s are based on odometer read-
i ngs i n ki l ometers. There are two mai ntenance sched-
ul es that show proper servi ce i nterval s. Use the
schedul e that best descri bes the condi ti ons the vehi -
cl e i s operated under. Schedule-A l i sts al l the sched-
ul ed mai ntenance to be performed under normal
operati ng condi ti ons. Schedule-B i s the schedul e for
vehi cl es that are operated under one or more of the
fol l owi ng condi ti ons:
Day and ni ght temperatures are bel ow freezi ng.
Stop and go dri vi ng.
Long peri ods of engi ne i dl i ng.
Dri vi ng i n dusty condi ti ons.
Short tri ps of l ess than 8 ki l ometers (5 mi l es).
Operati on at sustai ned hi gh speeds duri ng hot
weather above 32C (90F).
Taxi , pol i ce or del i very servi ce.
Trai l er towi ng.
AT EACH STOP FOR FUEL OR SCHEDULED
SERVICE STOP
Check engi ne oi l l evel .
Check engi ne cool ant l evel .
Vi sual l y i nspect i ntercool er for obstructi on.
Cl ean as necessary.
Vi sual l y i nspect radi ator for obstructi on. Cl ean
as necessary.
I nspect for fuel , oi l or cool ant l eaks.
I nspect battery cabl e connecti on and excessi ve
corrosi on.
I nspect for presence of water i n fuel fi l ter/water
separator, drai n i f necessary.
SCHEDULEA
1 000 KM
Change engi ne oi l fi l ter.
Check al l fl ui d l evel s.
Check correct torque, i ntake mani fol d mounti ng
nuts.
Check correct torque, exhaust mani fol d mount-
i ng nuts.
Check correct torque, turbocharger mounti ng
nuts.
Check correct torque, water mani fol d bol ts.
10 000 KM
20 000 KM
Repl ace ai r fi l ter el ement.
Check dri ve bel t tensi on.
Check gl ow pl ug operati on.
Retorque cylinder head bolts.*
* Engi nes equi pped wi th a steel head gasket do not
need thi s servi ce procedure performed. Refer to
Group 9, Engi nes for head gasket i denti fi cati on.
30 000 KM
40 000 KM
Repl ace fuel fi l ter/water separator el ement.**
50 000 KM
60 000 KM
Repl ace dri ve bel t.
Check engi ne smoke.
Repl ace engi ne cool ant.
70 000 KM
80 000 KM
90 000 KM
100 000 KM
EVERY 40 000 KM AFTER 80 000 KM
**The fuel fi l ter/water separator el ement shoul d be
repl aced once a year i f the vehi cl e i s dri ven l ess than
40 000 km annual l y or i f power l oss from fuel star-
vati on i s detected.
SCHEDULEB
500 KM
Check correct torque, i ntake mani fol d mounti ng
nuts.
Check correct torque, exhaust mani fol d mount-
i ng nuts.
Check correct torque, turbocharger mounti ng
nuts.
Check correct torque, water mani fol d bol ts.
1 000 KM
Check al l fl ui d l evel s.
5 000 KM
10 000 KM
15 000 KM
20 000 KM
Retorque cylinder head bolts.*
* Engi nes equi pped wi th a steel head gasket do not
need thi s servi ce procedure performed. Refer to
Group 9, Engi nes for head gasket i denti fi cati on.
25 000 KM
30 000 KM
35 000 KM
40 000 KM
Repl ace fuel fi l ter/water separator el ement.
45 000 KM
50 000 KM
55 000 KM
60 000 KM
65 000 KM
70 000 KM
75 000 KM
80 000 KM
85 000 KM
90 000 KM
95 000 KM
100 000 KM
SUSPENSION
CONTENTS
page page
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 4
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 11
ALIGNMENT
INDEX
page page
GENERAL INFORMATION
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
PRE-ALIGNMENT INSPECTION . . . . . . . . . . . . . 3
SERVICE PROCEDURES
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
WHEEL ALIGNMENT
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe posi ti on (Fi g. 1).
CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e rearward provi des posi ti ve caster. Ti l ti ng the
top of the knuckl e forward provi des negati ve caster.
Caster i s a di recti onal stabi l i ty angl e. Thi s angl e
enabl es the front wheel s to return to a strai ght
ahead posi ti on after turns.
CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re. The angl e i s not
adjustabl e, the damaged component(s) must be
repl aced to correct mi s-al i gnment.
WHEEL TOE POSITION i s the di fference
between the l eadi ng i nsi de edges and trai l i ng i nsi de
edges of the front ti res. I ncorrect wheel toe posi ti on
i s the most common cause of unstabl e steeri ng and
uneven ti re wear. The wheel toe posi ti on i s the final
front wheel al i gnment adjustment.
STEERING AXIS INCLINATION ANGLE i s
measured i n degrees and i s the angl e that the steer-
i ng knuckl es are ti l ted. The i ncl i nati on angl e has a
fi xed rel ati onshi p wi th the camber angl e. I t wi l l not
change except when a spi ndl e or bal l stud i s dam-
aged or bent. The angl e i s not adjustabl e, the dam-
aged component(s) must be repl aced to correct mi s-
al i gnment.
THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect
thrust angl e can cause off-center steeri ng and exces-
si ve ti re wear. Thi s angl e i s not adjustabl e, the dam-
aged component(s) must be repl aced to correct mi s-
al i gnment.
CAUTION: Do not attempt to modify any suspen-
sion or steering component by heating and bend-
ing.
ZG SUSPENSION 2 - 1
Fig. 1 Wheel Alignment Measurements
CAMBER WHEEL CENTER- LINE NEGATIVE CAM- BER ANGLE PIVOT CEN- TERLINE SCRUBRADIUS POSITIVE CAMBER (NOT SHOWN) TOP OF WHEEL OUTBOARD TRUE VER- TICAL TOE A FRONT OF VEHICLE NEGATIVE TOE (TOE OUT) B > A POSITIVE TOE (TOE IN) B < A TRUST ANGLE ANGLE OF REAR AXLE RELATIVE TO VEHICLE CENTER- LINE () AXLE POINTS RIGHT (+) AXLE POINTSLEFT CASTER KING PIN VERTICAL FRONT OF VEHICLE POSITIVE CASTER
2 - 2 SUSPENSION ZG
PRE-ALIGNMENT INSPECTION
Before starti ng wheel al i gnment, the fol l owi ng
i nspecti on i s necessary and must be compl eted.
(1) I nspect ti res for si ze, ai r pressure and tread
wear.
(2) I nspect front wheel beari ngs for wear or adjust-
ment.
(3) I nspect front wheel s and ti res for excessi ve
radi al or l ateral runout and bal ance.
(4) I nspect bal l studs, l i nkage pi vot poi nts and
steeri ng gear for l ooseness, roughness or bi ndi ng.
(5) I nspect suspensi on components for wear and
noi se.
SERVICE PROCEDURES
SPECIFICATIONS
ALIGNMENT
FRONT WHEELS
REAR AXLE
ADJUSTMENT PREFERRED RANGE
CASTER 7 6.5to 7.5
CAMBER
(not adjustable)
NA 1.13to + 0.13
TOE-IN
(each wheel)
0.12 0to + 0.22
Toe Differential Left to Right .05
ADJUSTMENT SPECIFICATION
THRUST ANGLE
(not adjustable)
.25
TOTAL TOE-IN
(not adjustable )
0.00 to + 0.5
ZG SUSPENSION 2 - 3
FRONT SUSPENSION
INDEX
page page
DESCRIPTION AND OPERATION
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 4
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
AXLE BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . 7
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . 6
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . 5
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 7
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 6
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 7
WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 10
FRONT SUSPENSION
The Grand Cherokee front suspensi on i s a l i nk/coi l
desi gn compri sed of (Fi g. 1):
Dri ve axl e (4WD), tube axl e (2WD)
Dual -acti on shock absorbers
Coi l spri ngs
Upper and l ower suspensi on arms
Stabi l i zer bar
Track bar
Jounce bumpers
Link/Coil Suspension: The l i nk/coi l suspensi on
al l ows each wheel to adapt to di fferent road surfaces
wi thout greatl y affecti ng the opposi te wheel . Wheel s
are attached to a hub/beari ngs whi ch bol ts to the
knuckl es. The hub/beari ng i s not servi ceabl e and i s
repl aced as a uni t. Steeri ng knuckl es pi vot on
Fig. 1 Front Suspension
LINKS SHOCK ABSORBER UPPER SUSPEN- SION ARM STABILIZER BAR PITMANARM COIL SPRING JOUNCEBUMPER LOWER SUSPEN- SION ARM STEERING DAMPER TRACK BAR AXLE TIE ROD TUBE
2 - 4 SUSPENSION ZG
repl aceabl e bal l studs attached to the axl e tube
yokes.
Shock Absorbers: The shock absorbers dampen
jounce and rebound moti on of the vehi cl e over vari -
ous road condi ti ons. The top of the shock absorbers
are bol ted to the body. The bottom of the shocks are
bol ted to the axl e brackets.
Coil Springs: The coi l spri ngs control ri de qual i ty
and mai ntai n proper ri de hei ght. The coi l spri ngs
mount up i n the wheel house whi ch i s part of the
uni ti zed body bracket. A rubber doughnut i sol ator i s
l ocated between the top of the spri ng and the body.
The bottom of the spri ng seats on a axl e pad and i s
retai ned wi th a cl i p.
Upper And Lower Suspension Arms: The sus-
pensi on arms use bushi ngs to i sol ate road noi se. The
suspensi on arms are bol ted to the frame and axl e
through the rubber bushi ngs. The l ower suspensi on
arm uses cam bol ts at the axl e to al l ow for caster
and pi ni on angl e adjustment. The suspensi on arm
travel i s l i mi ted through the use of jounce bumpers
i n compressi on and shocks absorbers i n rebound.
Stabilizer Bar: The stabi l i zer bar i s used to con-
trol vehi cl e body rol l duri ng turns. The spri ng steel
bar hel ps to control the vehi cl e body i n rel ati onshi p
to the suspensi on. The bar extends across the front
undersi de of the chassi s and connects to the frame
rai l s. Li nks are connected from the bar to the axl e
brackets. Stabi l i zer bar mounts are i sol ated by rub-
ber bushi ngs.
Track Bar: The track bar i s used to control front
axl e l ateral movement. The bar i s attached to a
frame rai l bracket wi th a bal l stud and i sol ated wi th
a bushi ng at the axl e bracket.
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.
CAUTION: Suspension components with rubber
bushings (except stabilizer bar) should be tightened
with the vehicle at normal ride height. It is impor-
tant to have the springs supporting the weight of
the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur. Rubber bushings must never
be lubricated.
NOTE: Periodic lubrication of the front suspension
(steering) system components is required. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
SHOCK DIAGNOSIS
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
SHOCK ABSORBER
REMOVAL
(1) Remove the nut, retai ner and grommet from
the upper stud i n the engi ne compartment (Fi g. 2).
(2) Remove the l ower nuts and bol ts from the axl e
bracket. Remove the shock absorber.
INSTALLATION
(1) Posi ti on the l ower retai ner and grommet on the
upper stud. I nsert the shock absorber through the
shock tower hol e.
(2) I nstal l the l ower bol ts and nuts. Ti ghten nuts
to 28 Nm (250 i n. l bs.).
(3) I nstal l the upper grommet and retai ner on the
stud i n the engi ne compartment. I nstal l the nut and
ti ghten to 23 Nm (17 ft. l bs.).
COIL SPRING
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support i t.
(2) Remove rear l ower suspensi on arm bol ts.
(3) Remove cal i per fl ex hose brackets from the
frame rai l s.
(4) Remove ABS sensor wi res from brackets.
ZG SUSPENSION 2 - 5
DESCRIPTION AND OPERATION (Continued)
(5) Di sconnect the stabi l i zer bar l i nk and shock
absorber from the axl e.
(6) Di sconnect the track bar from the frame rai l
bracket.
(7) Di sconnect the drag l i nk from the pi tman arm.
(8) Lower the axl e unti l the spri ng i s free from the
upper mount. Remove the coi l spri ng retai ner bol t
(Fi g. 2) and remove the spri ng.
(9) Remove the jounce bumper i f necessary from
the upper spri ng mount (Fi g. 2).
INSTALLATION
(1) I nstal l the jounce bumper on the upper spri ng
mount.
(2) Posi ti on the coi l spri ng on the axl e pad. I nstal l
the spri ng retai ner and bol t.
(3) Rai se the axl e i nto posi ti on unti l the spri ng
seats i n the upper mount.
(4) I nstal l l ower suspensi on arms and rear bol ts.
(5) I nstal l cal i per fl ex hose brackets to the frame
rai l s.
(6) I nstal l ABS sensor wi res i nto brackets.
(7) Connect the stabi l i zer bar l i nks and shock
absorbers to the axl e bracket. Connect the track bar
to the frame rai l bracket.
(8) I nstal l drag l i nk to pi tman arm.
(9) Remove the supports and l ower the vehi cl e.
(10) Ti ghten al l suspensi on components to proper
torque.
STEERING KNUCKLE
For servi ce procedures on the steeri ng knuckl e and
bal l studs refer to Group 3 Di fferenti al s And Dri v-
el i ne.
LOWER SUSPENSION ARM
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Pai nt or scri be al i gnment marks on the cam
adjusters and suspensi on arm for i nstal l ati on refer-
ence (Fi g. 3).
(3) Remove the l ower suspensi on arm nut, cam
and cam bol t from the axl e (Fi g. 4).
(4) Remove the nut and bol t from the frame rai l
bracket and remove the l ower suspensi on arm (Fi g.
4).
INSTALLATION
(1) Posi ti on the l ower suspensi on arm at the axl e
bracket and frame rai l bracket.
(2) I nstal l the rear bol ts and fi nger ti ghten the
new nuts.
(3) I nstal l a new cam bol t, cam and new nut i n the
axl e. Re-al i gn the reference marks.
(4) I nstal l the bol ts and fi nger ti ghten the new
nuts.
(5) Lower the vehi cl e.
(6) Ti ghten the axl e bracket nut to 115 Nm (85 ft.
l bs.).
Fig. 2 Coil Spring & Shock Absorber
NUT RETAINER GROMMET FWD GROMMET RETAINER SHOCK ABSORBER AXLE BRACKET COIL SPRING ISOLATOR JOUNCE BUMPER COIL SPRING VIEW IN DIRECTION OF ARROW W RETAINER VIEW IN DIRECTION OF ARROW Z
Fig. 3 Cam Adjuster
ADJUSTMENT CAM AXLE BRACKET BRACKET REIN- FORCEMENT LOWER SUSPENSION ARM
2 - 6 SUSPENSION ZG
REMOVAL AND INSTALLATION (Continued)
(7) Ti ghten the frame bracket nut to 176 Nm (130
ft. l bs.).
(8) Check the al i gnment i f new parts were
i nstal l ed.
UPPER SUSPENSION ARM
REMOVAL
(2) Remove the upper suspensi on arm nut and bol t
at the axl e bracket (Fi g. 4).
(3) Remove the nut and bol t at the frame rai l and
remove the upper suspensi on arm.
INSTALLATION
(1) Posi ti on the upper suspensi on arm at the axl e
and frame rai l .
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(4) Ti ghten the nut at the axl e and frame bracket
to 75 Nm (55 ft. l bs.).
AXLE BUSHING
REMOVAL
(1) Remove the upper suspensi on arm from axl e
(2) Posi ti on Recei ver 7932-1 (J-35581-1) over the
bushi ng i n the axl e and i nstal l Bushi ng Removal /I n-
stal l er (Fi g. 5).
(3) Remove the bushi ng by ti ghteni ng the Long
Nut.
NOTE: For two-wheel drive axles and right side on
Model 30 axle, do not remove Receiver 7932-1
(J-35581-1) at this time.
INSTALLATION
(1) Posi ti on new bushi ng, Recei ver and I nstal l er
on axl e (Fi g. 6).
(2) I nstal l the bushi ng by ti ghteni ng the Long Nut.
(3) Remove tool s and i nstal l the upper suspensi on
arm.
STABILIZER BAR
REMOVAL
Fig. 4 Upper & Lower Suspension Arms
AXLE HOUSING BOLT CAM BOLT LOWER USPENSION ARM CAM RIGHT SIDE SHOWN
Fig. 5 Bushing Removal
AXLE BRACKET SPECIAL TOOL 7604 (J-2147419) SPECIAL TOOL 79322 (J-355812) SPECIAL TOOL7603 (J-2147418) SPECIAL TOOL 79321 (J-355811)
Fig. 6 Bushing Installation
AXLE BRACKET SPECIAL TOOL 7604 (J-2147419) SPECIAL TOOL 79321 (J-355811) SPECIAL TOOL 79322 (J-355812) SPECIAL TOOL 7603 (J-2147418)
ZG SUSPENSION 2 - 7
(2) Remove upper l i nk nuts (Fi g. 7) and separate
l i nks from the stabi l i zer bar wi th Remover
MB-990635.
(3) Remove the stabi l i zer bar cl amps bol ts from
the frame rai l s and remove the stabi l i zer bar.
(4) Remove the stabi l i zer bar l i nk nuts from the
axl e brackets (Fi g. 7).
INSTALLATION
(1) Posi ti on the stabi l i zer bar on the frame rai l
and i nstal l the cl amps and bol ts. Ensure the bar i s
centered wi th equal spaci ng on both si des. Ti ghten
the bol ts to 54 Nm (40 ft. l bs.).
(2) I nstal l the l i nks i nto the stabi l i zer bar and axl e
brackets.
(3) Ti ghten the nuts at the axl e bracket end to 95
Nm (70 ft. l bs.).
(4) Ti ghten the stabi l i zer bar to l i nk nuts to 61
Nm (45 ft. l bs.).
Nm (70 ft. l bs.).
TRACK BAR
REMOVAL
(2) Remove the cotter pi n and nut from the bal l
stud end at the frame rai l bracket (Fi g. 8).
NOTE: Use a universal puller to separate the ball
stud from the frame rail bracket.
(3) Remove the bol t and fl ag nut from the axl e
shaft tube bracket (Fi g. 8). Remove the track bar.
INSTALLATION
(1) I nstal l the track bar at axl e tube bracket.
Loosel y i nstal l the retai ni ng bol t and fl ag nut.
(2) I t may be necessary to pry the axl e assembl y
over to i nstal l the track bar at the frame rai l . I nstal l
track bar at the frame rai l bracket. I nstal l the
retai ni ng nut on the stud.
(3) Ti ghten the bal l stud nut to 81 Nm (60 ft.
l bs.). I nstal l a new cotter pi n.
(5) Ti ghten the bol t at the axl e shaft tube bracket
to 75 Nm (55 ft. l bs.).
(6) Check al i gnment i f a new track bar was
i nstal l ed.
HUB BEARING
The Hub Beari ng i s servi ced as an assembl y.
REMOVAL
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake components from the axl e,
refer to Group 5 Brakes.
(4) Remove the cotter pi n, nut retai ner and axl e
hub nut (Fi g. 9).
Fig. 7 Stabilizer Bar
BUSHING CLAMP STABILIZER BAR LINK
Fig. 8 Track Bar
STUD PLATE FWD REINFORCEMENT PLATE NUT NUT COTTER PIN NUT FLAG NUT FRAME RAIL BRACKET TRACK BAR VIEW IN DIRECTION OF ARROW Y TRACK BAR VIEW IN DIRECTION OF ARROW W
2 - 8 SUSPENSION ZG
(5) Remove the hub mounti ng bol ts and remove
hub beari ng from the steeri ng knuckl e and axl e
shaft.
INSTALLATION
(1) I nstal l the hub beari ng and brake dust shi el d
to the knuckl e.
(2) I nstal l the hub to knuckl e bol ts and ti ghten to
102 Nm (75 ft. l bs.).
(3) I nstal l the hub washer and nut. Ti ghten the
hub nut to 237 Nm (175 ft. l bs.). I nstal l the nut
retai ner and a new cotter pi n.
(4) I nstal l the brake components, refer to Group 5
Brakes.
(5) I nstal l the wheel and ti re assembl y.
(6) Remove support and l ower the vehi cl e.
WHEEL MOUNTING STUDS
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove brake cal i per and rotor, refer to Group
5 Brakes for procedure.
(4) Remove stud from hub wi th Remover C-4150A
(Fi g. 10).
INSTALLATION
(1) I nstal l new stud i nto hub fl ange.
(2) I nstal l three washers onto stud, then i nstal l
l ug nut wi th the fl at si de of the nut agai nst the
washers.
(3) Ti ghten l ug nut unti l the stud i s pul l ed i nto
the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove l ug nut and washers.
(5) I nstal l the brake rotor and cal i per, refer to
Group 5 Brakes for procedure.
(6) I nstal l wheel and ti re assembl y, use new l ug
nut on stud or studs that were repl aced.
(7) Remove support and l ower vehi cl e.
Fig. 9 Hub Bearing & Knuckle
BRAKE SHIELD WASHER RETAINER COTTER PIN NUT HUB AND BEARING ASSEMBLY STEERING KNUCKLE BOLT TONE WHEEL (ABS)
Fig. 10 Wheel Stud Removal
REMOVER
WHEEL STUD
ZG SUSPENSION 2 - 9
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . . 23 Nm (17 ft. l bs.)
Lower Nut . . . . . . . . . . . . . . 28 Nm (250 i n. l bs.)
Suspension ArmUpper
Nuts . . . . . . . . . . . . . . . . . . . . 75 Nm (55 ft. l bs.)
Suspension ArmLower
Axl e Bracket Nut . . . . . . . . . . 115 Nm (85 ft. l bs.)
Frame Bracket Nut . . . . . . . 176 Nm (130 ft. l bs.)
Stabilizer Bar
Cl amp Bol t . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Li nk Upper Nut . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Li nk Lower Bol t . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Track Bar
Bal l Stud Nut . . . . . . . . . . . . . 81 Nm (60 ft. l bs.)
Axl e Bracket Bol t . . . . . . . . . . 75 Nm (55 ft. l bs.)
Track Bar Bracket
Bol ts . . . . . . . . . . . . . . . . . . . 121 Nm (90 ft. l bs.)
Nut . . . . . . . . . . . . . . . . . . . . 121 Nm (90 ft. l bs.)
Support Bol ts . . . . . . . . . . . . . 95 Nm (70 ft. l bs.)
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
(J-35581)
Nut, Long 7603 (J-2147418)
Bolt, Special 7604 (J-2147419)
Remover C-4150A
Remover Tie Rod End MB-990635
2 - 10 SUSPENSION ZG
REAR SUSPENSION
INDEX
page page
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . 11
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 12
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . 12
LOWER SUSPENSION ARM . . . . . . . . . . . . . . 13
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . 12
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 13
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 14
REAR SUSPENSION
The rear suspensi on i s l i nk/coi l desi gn compri sed of
(Fi g. 1):
Dri ve axl e
Coi l spri ngs
Track bar
Stabi l i zer bar
Jounce bumpers
Upper And Lower Suspension: The suspensi on
arms use bushi ngs to i sol ate road noi se. The suspen-
si on arms are bol ted to the body and axl e through
the rubber bushi ngs. The l ower suspensi on arm has
provi si on for the use of cam bol ts at the axl e to al l ow
for pi ni on angl e or thrust angl e adjustment. The
cams are avai l abl e as a servi ce ki t and are not
i nstal l ed at the factory. The suspensi on arm travel i s
l i mi ted through the of use jounce bumpers i n com-
pressi on and shock absorbers i n rebound.
jounce and rebound of the vehi cl e over vari ous road
condi ti ons. The top of the shock absorbers are bol ted
to the body. The bottom of the shocks are bol ted to
the axl e shock absorber bracket.
Coil Springs: The coi l spri ngs mount up i n the
fender shi el d that i s part of the uni ti zed body
bracket. There i s a rubber i sol ator between the top of
the spri ng and bracket to i sol ate road noi se. The bot-
tom of the spri ng seats on the axl e pad and i s
bar hel ps to equal i ze the vehi cl e body i n rel ati onshi p
to the suspensi on. The bar extends across the under-
si de of the chassi s and connects to the frame rai l s.
Li nks are connected from the bar to the axl e brack-
ets. Stabi l i zer bar are i sol ated by rubber bushi ngs.
Track Bar: The track bar i s used to control rear
axl e l ateral movement. The track bar i s attached to a
frame rai l bracket and an axl e bracket. I t i s i sol ated
wi th bushi ngs at both ends.
CAUTION: Suspension components that use rubber
bushings (except stabilizer bar) should be tightened
with the vehicle at normal ride height. This will pre-
vent premature failure of the bushing and maintain
ride comfort. Rubber bushings must never be lubri-
cated.
Fig. 1 Rear Suspension
STABILIZERBAR COIL SPRING UPPER SUSPEN- SION ARM
TRACK BAR
LOWER SUSPEN- SION ARM DRIVE AXLE SHOCK ABSORBER
ZG SUSPENSION 2 - 11
SHOCK DIAGNOSIS
SHOCK ABSORBER
REMOVAL
(2) Remove the upper nut and retai ner from the
frame rai l stud (Fi g. 2).
(3) Remove the l ower nut and bol t from the axl e
INSTALLATION
(1) I nstal l the shock absorber on the upper frame
rai l stud. I nstal l the shock absorber on the axl e
bracket.
(2) I nstal l the retai ner and nut on the stud.
Ti ghten the upper nut to 70 Nm (52 ft. l bs.).
(3) I nstal l l ower bol t and nut fi nger ti ght.
(5) Ti ghten the l ower nut to 92 Nm (68 ft. l bs.).
COIL SPRING
REMOVAL
absorber from the axl e bracket.
bracket.
upper mount seat. Remove the coi l spri ng retai ner
bol t (Fi g. 2) and remove the spri ng.
INSTALLATION
I nspect i sol ator for damage or wear. Repl ace the
i sol ator i f necessary before i nstal l i ng spri ng.
the spri ng retai ner and bol t. Ti ghten the bol t to 22
Nm (16 ft. l bs.).
(5) Ti ghten the track bar and shock absorber to
speci fi ed torque.
Fig. 2 Rear Coil Spring & Shock Absorber
COIL SPRING CLIP AXLE BRACKET FRAME RAIL STUD RETAINERNUT SHOCK ABSORBER COIL SPRING VIEW IN DIRECTION OF ARROW Z
REMOVAL
(2) Remove the l ower suspensi on arm nut and bol t
(3) Remove the nut and bol t (Fi g. 3) at the frame
rai l and remove the l ower suspensi on arm.
INSTALLATION
(4) Ti ghten the l ower suspensi on arm nuts to 177
Nm (130 ft. l bs.).
REMOVAL
at the axl e bracket (Fi g. 3). Remove the ABS wi re
bracket from the arm.
INSTALLATION
and frame rai l .
I nstal l the ABS wi re bracket onto the arm.
(4) Ti ghten the upper suspensi on arm nuts to 75
Nm (55 ft. l bs.).
STABILIZER BAR
REMOVAL
(1) Rai se and support the vehi cl e. Remove one
wheel and ti re.
(2) Di sconnect the stabi l i zer bar l i nks from the
(3) Lower the exhaust by di sconnecti ng the muffl er
and tai l pi pe hangers.
(4) Di sconnect the stabi l i zer bar from the l i nks.
(5) Di sconnect the stabi l i zer bar cl amps from the
frame rai l s. Remove the stabi l i zer bar.
INSTALLATION
(2) I nstal l the l i nks and grommets onto the stabi -
l i zer bar and axl e brackets. I nstal l the nuts and
(3) Connect the muffl er and tai l pi pe to thei r
hangers.
FWD LOWER SUSPEN- SION ARM UPPER SUSPENSION ARM
Fig. 4 Rear Stabilizer Bar
LINK RETAINER GROMMET AXLE BRACKET RETAINER GROMMET STABILIZERBAR BUSHING CLAMP
TRACK BAR
REMOVAL
(2) Remove the bol t and nut from the frame rai l
bracket (Fi g. 5).
(3) Remove the bol t from the axl e tube bracket
(Fi g. 5). Remove the track bar.
INSTALLATION
(1) I nstal l the track bar to the axl e bracket and
i nstal l a new bol t.
over to i nstal l the track bar. I nstal l the track bar to
the frame rai l bracket. Loosel y i nstal l the bol t and
fl ag nut.
(4) Ti ghten the track bar bol ts 100 Nm (74 ft.
l bs.).
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Lower Nut . . . . . . . . . . . . . . . . 92 Nm (68 ft. l bs.)
Suspension ArmUpper
Nuts . . . . . . . . . . . . . . . . . . . . 75 Nm (55 ft. l bs.)
Suspension ArmLower
Nuts . . . . . . . . . . . . . . . . . . 177 Nm (130 ft. l bs.)
Stabilizer Bar
Li nk Nut . . . . . . . . . . . . . . . . . 36 Nm (27 ft. l bs.)
Track Bar
Frame Bracket Nut . . . . . . . . 100 Nm (74 ft. l bs.)
Axl e Bracket Bol t . . . . . . . . . 100 Nm (74 ft. l bs.)
Fig. 5 Rear Track Bar
TRACK BAR AXLE BRACKET FRAME BRACKET
SUSPENSION
CONTENTS
page page
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 6
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 14
ALIGNMENT
INDEX
page page
GENERAL INFORMATION
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 1
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 2
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
WHEEL ALIGNMENT
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe posi ti on (Fi g. 1).
CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e rearward provi des posi ti ve caster. Ti l ti ng the
top of the knuckl e forward provi des negati ve caster.
Caster i s a di recti onal stabi l i ty angl e. Thi s angl e
enabl es the front wheel s to return to a strai ght
ahead posi ti on after turns.
CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re. The angl e i s not
adjustabl e, damaged component(s) must be repl aced
to correct the camber angl e.
WHEEL TOE POSITION i s the di fference
between the l eadi ng i nsi de edges and trai l i ng i nsi de
edges of the front ti res. I ncorrect wheel toe posi ti on
i s the most common cause of unstabl e steeri ng and
uneven ti re wear. The wheel toe posi ti on i s the final
front wheel al i gnment adjustment.
STEERING AXIS INCLINATION ANGLE i s
measured i n degrees and i s the angl e that the steer-
i ng knuckl es are ti l ted. The i ncl i nati on angl e has a
fi xed rel ati onshi p wi th the camber angl e. I t wi l l not
change except when a spi ndl e or bal l stud i s dam-
aged or bent. The angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the steeri ng
axi s i ncl i nati on angl e.
THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect
thrust angl e can cause off-center steeri ng and exces-
si ve ti re wear. Thi s angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the thrust
angl e.
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
ZG SUSPENSION 2 - 1
SERVICE PROCEDURES
PRE-ALIGNMENT
Before starti ng wheel al i gnment, the fol l owi ng
i nspecti on and necessary correcti ons must be com-
pl eted. Refer to Suspensi on and Steeri ng System
Di agnosi s Chart for addi ti onal i nformati on.
(1) I nspect ti res for si ze, ai r pressure and tread
wear.
(2) I nspect front wheel beari ngs for wear.
(3) I nspect front wheel s for excessi ve radi al or l at-
eral runout and bal ance.
(4) I nspect bal l studs, l i nkage pi vot poi nts and
steeri ng gear for l ooseness, roughness or bi ndi ng.
(5) I nspect suspensi on components for wear and
noi se.
Fig. 1 Wheel Alignment Measurements
2 - 2 SUSPENSION ZG
WHEEL ALIGNMENT
Before each al i gnment readi ng the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down three ti mes. Al ways rel ease the bumper i n the
down posi ti on.
CAMBER
The wheel camber angl e i s preset. Thi s angl e i s not
adjustabl e and cannot be al tered.
CASTER
Check the caster of the front axl e for correct angl e.
Be sure the axl e i s not bent or twi sted. Road test the
vehi cl e and observe the steeri ng wheel return-to-cen-
ter posi ti on. Low caster wi l l cause poor steeri ng
wheel returnabi l i ty.
Duri ng the road test, turn the vehi cl e to both the
l eft and ri ght. I f the steeri ng wheel returns to the
center posi ti on unassi sted, the caster angl e i s correct.
However, i f steeri ng wheel does not return toward
the center posi ti on unassi sted, a l ow caster angl e i s
probabl e.
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
2. Loose or worn steering or
suspension components
2. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN STEERING 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Replace wheel bearings.
necessary.
3. Tire pressure. 3. Adjust tire pressure.
EXCESSIVE STEERING EFFORT 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Column coupler binding. 2. Replace coupler.
VEHICLE PULLS TO ONE SIDE 1. Tire pressure. 1. Adjust tire pressure.
necessary.
4. Radial tire lead. 4. Rotate or replace tire as
necessary.
5. Brake pull. 5. Repair brake as necessary.
6. Weak or broken spring. 6. Replace spring.
ZG SUSPENSION 2 - 3
Caster can be adjusted by l ooseni ng and rotati ng
the cams on the l ower suspensi on arm (Fi g. 2).
Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3,
Differential and Driveline for additional infor-
mation.
TOE POSITION (LHD)
NOTE: The wheel toe position adjustment should
be the final adjustment.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the steeri ng wheel . Center and
secure the steeri ng wheel .
(2) Loosen the adjustment sl eeve cl amp bol ts (Fi g.
3).
(3) Adjust the ri ght wheel toe posi ti on wi th the
drag l i nk (Fi g. 4). Turn the sl eeve unti l the ri ght
wheel i s at the correct posi ti ve TOE-I N posi ti on.
Posi ti on the cl amp bol ts as shown (Fi g. 3) and
ti ghten to:
Vehi cl es wi th 2.5L engi ne: 27 Nm (20 ft. l bs.)
NOTE: Make sure the toe setting does not change
during clamp tightening.
(4) Adjust the l eft wheel toe posi ti on wi th the ti e
rod. Turn the sl eeve unti l the l eft wheel i s at the
same TOE-I N posi ti on as the ri ght wheel . Posi ti on
the cl amp bol ts as shown (Fi g. 3) and ti ghten to:
(5) Veri fy the toe setti ng.
TOE POSITION (RHD)
NOTE: The wheel toe position adjustment should
be the final adjustment.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the steeri ng wheel . Center and
secure the steeri ng wheel .
(2) Loosen the adjustment sl eeve cl amp bol ts (Fi g.
5).
(3) Adjust the l eft wheel toe posi ti on wi th the drag
l i nk (Fi g. 5). Turn the sl eeve unti l the l eft wheel i s at
the correct posi ti ve TOE-I N posi ti on. Posi ti on the
cl amp bol ts to thei r ori gi nal posi ti on and ti ghten to:
Fig. 2 Cam Adjuster
Fig. 3 Drag Link and Tie Rod Clamp (LHD)
Fig. 4 Steering Linkage (LHD)
2 - 4 SUSPENSION ZG
(4) Adjust the ri ght wheel toe posi ti on wi th the ti e
rod. Turn the sl eeve unti l the ri ght wheel i s at the
same TOE-I N posi ti on as the l eft wheel . Posi ti on the
cl amp bol t to i ts ori gi nal posi ti on and ti ghten to:
(5) Veri fy the toe setti ng.
SPECIFICATIONS
ALIGNMENT
FRONT WHEELS
REAR AXLE
Fig. 5 Steering Linkage (RHD)
ADJUSTMENT PREFERRED RANGE
CASTER 7 6.5to 7.5
CAMBER
(not adjustable)
NA 1.13to +
0.13
TOE-IN
(each wheel)
0.12 0to + 0.22
Toe Differential Left to Right .05
ADJUSTMENT SPECIFICATION
THRUST ANGLE
(not adjustable)
.25
TOTAL TOE-IN
(not adjustable )
0.00 to + 0.5
ZG SUSPENSION 2 - 5
FRONT SUSPENSION
INDEX
page page
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 6
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 7
AXLE BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . 9
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . . 11
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . 8
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . 8
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 10
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . 8
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 9
WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . 11
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 13
FRONT SUSPENSION
The front suspensi on i s a l i nk/coi l desi gn (Fi g. 1).
Thi s desi gn i s used on Left Hand Dri ve (LHD) and
Ri ght Hand Dri ve (RHD) vehi cl es. The suspensi on i s
compri sed of:
Dri ve axl e (4WD), tube axl e (2WD)
Coi l spri ngs
Stabi l i zer bar
Track bar
Jounce Bumper
Link/Coil Suspension: The l i nk/coi l suspensi on
al l ows each wheel to adapt to di fferent road surfaces
wi thout greatl y affecti ng the opposi te wheel . Wheel s
are attached to a hub/beari ngs whi ch bol ts to the
knuckl es. The hub/beari ng i s not servi ceabl e and i s
repl aced as a uni t. Steeri ng knuckl es pi vot on
repl aceabl e bal l studs attached to the axl e tube
yokes.
jounce and rebound moti on of the vehi cl e over vari -
ous road condi ti ons. The top of the shock absorbers
are bol ted to the body. The bottom of the shocks are
bol ted to the axl e brackets.
Coil Springs: The coi l spri ngs control ri de qual i ty
and mai ntai n proper ri de hei ght. The coi l spri ngs
mount up i n the wheel house whi ch i s part of the
uni ti zed body bracket. A rubber doughnut i sol ator i s
l ocated between the top of the spri ng and the body.
The bottom of the spri ng seats on a axl e pad and i s
si on arms are bol ted to the frame and axl e through
the rubber bushi ngs. The l ower suspensi on arm uses
cam bol ts at the axl e to al l ow for caster and pi ni on
angl e adjustment. The suspensi on arm travel i s l i m-
i ted through the use of jounce bumpers i n compres-
si on and shocks absorbers i n rebound.
bar hel ps to control the vehi cl e body i n rel ati onshi p
to the suspensi on. The bar extends across the front
undersi de of the chassi s and connects to the frame
rai l s. Li nks are connected from the bar to the axl e
brackets. Stabi l i zer bar mounts are i sol ated by rub-
ber bushi ngs.
Track Bar: The track bar i s used to control front
axl e l ateral movement. The bar i s attached to a
frame rai l bracket wi th a bal l stud and i sol ated wi th
a bushi ng at the axl e bracket.
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
2 - 6 SUSPENSION ZG
NOTE: The service procedures and torque specifi-
cations are the same for LHD and RHD vehicles.
The following service procedures and pictures were
developed with a LHD vehicle.
SHOCK DIAGNOSIS
Fig. 1 Front Suspension (LHD)
ZG SUSPENSION 2 - 7
SHOCK ABSORBER
REMOVAL
(1) Remove the nut, retai ner and grommet from
the upper stud i n the engi ne compartment (Fi g. 2).
(2) Remove the l ower nuts and bol ts from the axl e
INSTALLATION
(1) Posi ti on the l ower retai ner and grommet on the
upper stud. I nsert the shock absorber through the
shock tower hol e.
(2) I nstal l the l ower bol ts and nuts. Ti ghten nuts
to 28 Nm (250 i n. l bs.).
(3) I nstal l the upper grommet and retai ner on the
stud i n the engi ne compartment. I nstal l the nut and
COIL SPRING
REMOVAL
(2) Remove rear l ower suspensi on arm bol ts.
(3) Remove cal i per fl ex hose brackets from the
frame rai l s.
(4) Remove ABS sensor wi res from brackets.
absorber from the axl e.
bracket.
(7) Di sconnect the drag l i nk from the pi tman arm.
upper mount. Remove the coi l spri ng retai ner bol t
(Fi g. 2) and remove the spri ng.
(9) Remove the jounce bumper i f necessary from
the upper spri ng mount (Fi g. 2).
INSTALLATION
(1) I nstal l the jounce bumper on the upper spri ng
mount.
the spri ng retai ner and bol t. Ti ghten bol t to 22 Nm
(16 ft l b).
(4) I nstal l l ower suspensi on arms and rear bol ts.
(5) I nstal l cal i per fl ex hose brackets to the frame
rai l s.
(6) I nstal l ABS sensor wi res i nto brackets.
(8) I nstal l drag l i nk to pi tman arm.
(10) Ti ghten al l suspensi on components to proper
torque.
STEERING KNUCKLE
For servi ce procedures on the steeri ng knuckl e and
bal l joi nts refer to Group 3 Di fferenti al s And Dri v-
el i ne.
REMOVAL
(2) Pai nt or scri be al i gnment marks on the cam
adjusters and suspensi on arm for i nstal l ati on refer-
ence (Fi g. 3).
(3) Remove the l ower suspensi on arm nut, cam
and cam bol t from the axl e (Fi g. 4).
(4) Remove the nut and bol t from the frame rai l
bracket and remove the l ower suspensi on arm (Fi g.
4).
Fig. 2 Coil Spring & Shock Absorber
2 - 8 SUSPENSION ZG
INSTALLATION
(2) I nstal l the rear bol ts and fi nger ti ghten the
new nuts.
(3) I nstal l a new cam bol t, cam and new nut i n the
axl e. Re-al i gn the reference marks.
(4) I nstal l the bol ts and fi nger ti ghten the new
nuts.
(6) Ti ghten the axl e bracket nut to 115 Nm (85 ft.
l bs.).
(7) Ti ghten the frame bracket nut to 176 Nm (130
ft. l bs.).
(8) Check the al i gnment i f new parts were
i nstal l ed.
REMOVAL
INSTALLATION
and frame rai l .
(4) Ti ghten the nut at the axl e and frame bracket
to 75 Nm (55 ft. l bs.).
AXLE BUSHING
REMOVAL
(1) Remove the upper suspensi on arm from axl e.
(2) Posi ti on spacer 7932-1 (J-35581-1) over the
bushi ng i n the axl e for two-wheel dri ve axl es and
ri ght si de on Model 30 axl e.
(3) I nstal l Bushi ng Removal /I nstal l er (Fi g. 5).
(4) Remove the bushi ng by ti ghteni ng the Long
Nut.
NOTE: For two-wheel drive axles and right side on
Model 30 axle, do not remove spacer 7932-1
(J-35581-1). This spacer is need for installation.
Fig. 3 Cam Adjuster
Fig. 5 Bushing Removal
ZG SUSPENSION 2 - 9
INSTALLATION
(1) Posi ti on new bushi ng, Recei ver and I nstal l er
on axl e (Fi g. 6).
(2) I nstal l the bushi ng by ti ghteni ng the Long Nut.
(3) Remove tool s and i nstal l the upper suspensi on
arm.
STABILIZER BAR
REMOVAL
(2) Remove upper l i nk bol ts (Fi g. 7) and separate
l i nks from the stabi l i zer bar wi th Remover
MB-990635.
(3) Remove the stabi l i zer bar cl amps bol ts from
the frame rai l s and remove the stabi l i zer bar.
(4) Remove the stabi l i zer bar l i nk nuts from the
INSTALLATION
(2) I nstal l the l i nks i nto the stabi l i zer bar and axl e
brackets.
Nm (70 ft. l bs.).
(4) Ti ghten the stabi l i zer bar to l i nk nuts to 61
Nm (45 ft. l bs.).
Nm (70 ft. l bs.).
TRACK BAR
REMOVAL
stud end at the frame rai l bracket (Fi g. 8).
NOTE: Use a universal puller to separate the ball
stud from the frame rail bracket.
(3) Remove the bol t and fl ag nut from the axl e
shaft tube bracket (Fi g. 8). Remove the track bar.
INSTALLATION
(1) I nstal l the track bar at axl e tube bracket.
Loosel y i nstal l the retai ni ng bol t and fl ag nut.
over to i nstal l the track bar at the frame rai l . I nstal l
track bar at the frame rai l bracket. I nstal l the
retai ni ng nut on the stud.
(3) Ti ghten the bal l stud nut to 81 Nm (60 ft.
l bs.). I nstal l a new cotter pi n.
(5) Ti ghten the bol t at the axl e shaft tube bracket
to 75 Nm (55 ft. l bs.).
(6) Check al i gnment i f a new track bar was
i nstal l ed.
Fig. 6 Bushing Installation
Fig. 7 Stabilizer Bar
HUB BEARING
REMOVAL
(3) Remove the brake cal i per, rotor and ABS wheel
speed sensor, refer to Group 5 Brakes.
(4) Remove the cotter pi n, nut retai ner and axl e
hub nut (Fi g. 9).
(5) Remove the hub mounti ng bol ts and remove
hub beari ng from the steeri ng knuckl e and axl e
shaft.
INSTALLATION
(1) I nstal l the hub beari ng and brake dust shi el d
to the knuckl e.
102 Nm (75 ft. l bs.).
(3) I nstal l the hub washer and nut. Ti ghten the
hub nut to 237 Nm (175 ft. l bs.). I nstal l the nut
retai ner and a new cotter pi n.
(4) I nstal l the brake rotor, cal i per and ABS wheel
speed sensor, refer to Group 5 Brakes.
WHEEL MOUNTING STUDS
REMOVAL
(3) Remove brake cal i per and rotor, refer to Group
5 Brakes for procedure.
Fig. 9 Hub Bearing & Knuckle
Fig. 8 Track Bar
(4) Remove stud from hub wi th Remover C-4150A
(Fi g. 10).
INSTALLATION
(1) I nstal l new stud i nto hub fl ange.
(2) I nstal l three washers onto stud, then i nstal l
l ug nut wi th the fl at si de of the nut agai nst the
washers.
(3) Ti ghten l ug nut unti l the stud i s pul l ed i nto
the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove l ug nut and washers.
(5) I nstal l the brake rotor and cal i per, refer to
Group 5 Brakes for procedure.
(6) I nstal l wheel and ti re assembl y, use new l ug
nut on stud or studs that were repl aced.
(7) Remove support and l ower vehi cl e.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Suspension ArmUpper
Nuts . . . . . . . . . . . . . . . . . . . . 75 Nm (55 ft. l bs.)
Suspension ArmLower
Axl e Bracket Nut . . . . . . . . . . 115 Nm (85 ft. l bs.)
Frame Bracket Nut . . . . . . . 176 Nm (130 ft. l bs.)
Stabilizer Bar
Li nk Upper Nut . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Li nk Lower Bol t . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Track Bar
Bal l Stud Nut . . . . . . . . . . . . . 81 Nm (60 ft. l bs.)
Axl e Bracket Bol t . . . . . . . . . . 75 Nm (55 ft. l bs.)
Track Bar Bracket
Bol ts . . . . . . . . . . . . . . . . . . . 121 Nm (90 ft. l bs.)
Nut . . . . . . . . . . . . . . . . . . . . 121 Nm (90 ft. l bs.)
Support Bol ts . . . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Hub Bearing
Bol ts . . . . . . . . . . . . . . . . . . . 102 Nm (75 ft. l bs.)
Fig. 10 Wheel Stud Removal
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
(J-35581)
Nut, Long 7603 (J-2147418)
Bolt, Special 7604 (J-2147419)
Remover C-4150A
Remover Tie Rod End MB-990635
REAR SUSPENSION
INDEX
page page
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . 14
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 15
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . 15
LOWER SUSPENSION ARM . . . . . . . . . . . . . . 16
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . 15
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . 16
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . 16
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 17
REAR SUSPENSION
The rear suspensi on i s l i nk/coi l desi gn compri sed of
(Fi g. 1):
Dri ve axl e
Coi l spri ngs
Track bar
Stabi l i zer bar
si on arms are bol ted to the body and axl e through
the rubber bushi ngs. The l ower suspensi on arm has
provi si on for the use of cam bol ts at the axl e to al l ow
for pi ni on angl e or thrust angl e adjustment. The
cams are avai l abl e as a servi ce ki t and are not
i nstal l ed at the factory. The suspensi on arm travel i s
l i mi ted through the of use jounce bumpers i n com-
pressi on and shock absorbers i n rebound.
jounce and rebound of the vehi cl e over vari ous road
condi ti ons. The top of the shock absorbers are bol ted
to the body. The bottom of the shocks are bol ted to
the axl e shock absorber bracket.
Coil Springs: The coi l spri ngs mount up i n the
fender shi el d that i s part of the uni ti zed body
bracket. There i s a rubber i sol ator between the top of
the spri ng and bracket to i sol ate road noi se. The bot-
tom of the spri ng seats on the axl e pad and i s
bar hel ps to equal i ze the vehi cl e body i n rel ati onshi p
to the suspensi on. The bar extends across the under-
si de of the chassi s and connects to the frame rai l s.
Li nks are connected from the bar to the axl e brack-
ets. Stabi l i zer bar are i sol ated by rubber bushi ngs.
Track Bar: The track bar i s used to control rear
axl e l ateral movement. The track bar i s attached to a
frame rai l bracket and an axl e bracket. I t i s i sol ated
wi th bushi ngs at both ends.
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. This
will maintain vehicle ride comfort and prevent pre-
mature bushing wear.
Fig. 1 Rear Suspension
SHOCK DIAGNOSIS
SHOCK ABSORBER
REMOVAL
(2) Remove the upper nut and retai ner from the
frame rai l stud (Fi g. 2).
(3) Remove the l ower nut and bol t from the axl e
INSTALLATION
(1) I nstal l the shock absorber on the upper frame
rai l stud. I nstal l the shock absorber on the axl e
bracket.
(2) I nstal l the retai ner and nut on the stud.
Ti ghten the upper nut to 70 Nm (52 ft. l bs.).
(3) I nstal l l ower bol t and nut fi nger ti ght.
(5) Ti ghten the l ower nut to 92 Nm (68 ft. l bs.).
COIL SPRING
REMOVAL
absorber from the axl e bracket.
bracket.
upper mount seat. Remove the coi l spri ng retai ner
bol t (Fi g. 2) and remove the spri ng.
INSTALLATION
I nspect i sol ator for damage or wear. Repl ace the
i sol ator i f necessary before i nstal l i ng spri ng.
the spri ng retai ner and bol t. Ti ghten the bol t to 22
Nm (16 ft. l bs.).
(5) Ti ghten the track bar and shock absorber to
speci fi ed torque.
Fig. 2 Rear Coil Spring & Shock Absorber
REMOVAL
(2) Remove the l ower suspensi on arm nut and bol t
(3) Remove the nut and bol t (Fi g. 3) at the frame
rai l and remove the l ower suspensi on arm.
INSTALLATION
(4) Ti ghten the l ower suspensi on arm nuts to 177
Nm (130 ft. l bs.).
REMOVAL
at the axl e bracket (Fi g. 3). Remove the ABS wi re
bracket from the arm.
INSTALLATION
and frame rai l .
I nstal l the ABS wi re bracket onto the arm.
Nm (55 ft. l bs.).
STABILIZER BAR
REMOVAL
(1) Rai se and support the vehi cl e. Remove one
wheel and ti re.
(2) Di sconnect the stabi l i zer bar l i nks from the
(3) Lower the exhaust by di sconnecti ng the muffl er
and tai l pi pe hangers.
(4) Di sconnect the stabi l i zer bar from the l i nks.
(5) Di sconnect the stabi l i zer bar cl amps from the
frame rai l s. Remove the stabi l i zer bar.
INSTALLATION
(2) I nstal l the l i nks and grommets onto the stabi -
l i zer bar and axl e brackets. I nstal l the nuts and
(3) Connect the muffl er and tai l pi pe to thei r
hangers.
TRACK BAR
REMOVAL
(2) Remove the bol t and nut from the frame rai l
bracket (Fi g. 5).
(3) Remove the bol t from the axl e tube bracket
(Fi g. 5). Remove the track bar.
Fig. 4 Rear Stabilizer Bar
INSTALLATION
(1) I nstal l the track bar to the axl e bracket and
i nstal l a new bol t.
over to i nstal l the track bar. I nstal l the track bar to
the frame rai l bracket. Loosel y i nstal l the bol t and
fl ag nut.
(4) Ti ghten the track bar bol ts 100 Nm (74 ft.
l bs.).
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Suspension ArmUpper
Nuts . . . . . . . . . . . . . . . . . . . . 75 Nm (55 ft. l bs.)
Suspension ArmLower
Nuts . . . . . . . . . . . . . . . . . . 177 Nm (130 ft. l bs.)
Stabilizer Bar
Li nk Nut . . . . . . . . . . . . . . . . . 36 Nm (27 ft. l bs.)
Track Bar
Frame Bracket Nut . . . . . . . . 100 Nm (74 ft. l bs.)
Axl e Bracket Bol t . . . . . . . . . 100 Nm (74 ft. l bs.)
Fig. 5 Rear Track Bar
DIFFERENTIAL AND DRIVELINE
CONTENTS
page page
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 15
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 50
216 RBA AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 87
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . 1
PROPELLER SHAFTS
INDEX
page page
GENERAL INFORMATION
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . 2
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROPELLER SHAFT JOINT ANGLE . . . . . . . . . . 2
PROPELLER SHAFT JOINTS . . . . . . . . . . . . . . . 2
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . 1
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT ANGLE MEASUREMENT . . 6
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . 7
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . 8
DISASSEMBLY AND ASSEMBLY
DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . 10
SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . 8
CLEANING AND INSPECTION
SINGLE AND DOUBLE CARDAN JOINT . . . . . . 13
ADJUSTMENTS
AXLE PINION ANGLE ADJUSTMENT . . . . . . . . 13
FRONT PROPELLER SHAFT
MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 14
GENERAL INFORMATION
PROPELLER SHAFTS
The functi on of a propel l er shaft i s to transmi t
power from one poi nt to another i n a smooth acti on.
The shaft i s desi gned to send torque through an
angl e from the transmi ssi on (transfer case on 4WD
vehi cl es) to the axl e (Fi g. 1).
The propel l er shaft must operate through con-
stantl y changi ng rel ati ve angl es between the trans-
mi ssi on and axl e. I t must al so be capabl e of changi ng
l ength whi l e transmi tti ng torque. The axl e ri des sus-
pended by spri ngs i n a fl oati ng moti on. Thi s means
the propel l er shaft must be abl e to change angl es
when goi ng over vari ous roads. Thi s i s accompl i shed
through uni versal joi nts, whi ch permi t the propel l er
shaft to operate at di fferent angl es. The sl i p joi nts (or
yokes) permi t contracti on or expansi on.
Tubul ar propel l er shafts are bal anced by the man-
ufacturer wi th wei ghts spot wel ded to the tube.
The propel l er shaft i s desi gned and bui l t wi th the
yoke l ugs i n l i ne wi th each other whi ch i s cal l ed
phasi ng. Thi s desi gn produces the smoothest runni ng
condi ti on. An out of phase shaft can cause a vi bra-
ti on.
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered. This
will prevent the undercoating from causing an
out of balance condition and vibration.
CAUTION: Use exact replacement parts for attach-
ing the propeller shafts. This will ensure safe oper-
ation. The specified torque must always be applied
when tightening the fasteners.
ZG DIFFERENTIAL AND DRIVELINE 3 - 1
There are two front propel l er shafts used on ZJ
vehi cl es. Both shafts use a doubl e cardan joi nt at the
transfer case end. The di fference between the two
shafts i s how they connect to the front axl e and how
they handl e the vari ati on i n l ength requi red by sus-
pensi on travel . The one shaft has a Constant Vel oci ty
(CV) joi nt at the axl e end of the propel l er shaft whi ch
contracts and extends as necessary. The CV joi nt has
a spl i ned shaft whi ch al l ows the overal l shaft l ength
to be adjusted for opti mum joi nt travel . Thi s spl i ne
shaft i s then l ocked i n pl ace wi th a nut. The second
shaft uses a si ngl e Cardan uni versal joi nt at the axl e
and a sl i p yoke to handl e l ength changes.
PROPELLER SHAFT JOINTS
Three di fferent types of propel l er shaft joi nts are
used i n ZJ vehi cl es (Fi g. 2), (Fi g. 3), and (Fi g. 4).
None of the three joi nts are servi ci bl e. I f worn or
damaged, they must be repl aced. I f a vehi cl e has a
damaged or worn Constant Vel oci ty (CV) joi nt, or
boot, the propel l er shaft must be repl aced.
PROPELLER SHAFT JOINT ANGLE
When two shafts come together at a common joi nt,
the bend that i s formed i s cal l ed the operati ng angl e.
The l arger the angl e, the l arger the amount of accel -
erati on and decel erati on of the joi nt. Thi s speedi ng
up and sl owi ng down of the joi nt must be cancel l ed
to produce a smooth power fl ow. Thi s i s done through
the phasi ng of a propel l er shaft and ensuri ng that
the proper propel l er shaft joi nt worki ng angl es are
mai ntai ned.
A propel l er shaft i s properl y phased when the yoke
ends are i n the same pl ane, or i n l i ne. A twi sted
shaft wi l l make the yokes out of phase and cause a
noti ceabl e vi brati on.
When taki ng propel l er shaft joi nt angl e measure-
ments, or checki ng the phasi ng, of two pi ece shafts,
consi der each shaft separatel y.
I deal l y the dri vel i ne system shoul d have;
Angl es that are equal or opposi te wi thi n 1
degree of each other.
Have a 3 degree maxi mum operati ng angl e.
Have at l east a 1/2 degree conti nuous operati ng
(propel l er shaft) angl e.
Engi ne speed (rpm) i s the mai n factor i n determi n-
i ng the maxi mum al l owabl e operati ng angl e. As a
gui de to the maxi mum normal operati ng angl es refer
to (Fi g. 5).
Fig. 1 Front & Rear Propeller Shafts
TRANSFER CASE
REAR AXLE
STRAP
Fig. 2 Single Cardan U-Joint
CROSS SEAL CAP AND NEEDLE BEAR- INGS
3 - 2 DIFFERENTIAL AND DRIVELINE ZG
LUBRICATION
The sl i p yoke on the one styl e of front propel l er
shaft i s equi pped wi th a l ubri cati on fi tti ng. Use a
mul ti -purpose NLGI Grade 2 EP l ubri cant. The fac-
tory i nstal l ed uni versal joi nts are l ubri cated for the
l i fe of the vehi cl e and do not need l ubri cati on. Al l
uni versal joi nts shoul d be i nspected for l eakage and
damage each ti me the vehi cl e i s servi ced. I f seal
l eakage or damage exi sts, the uni versal joi nt shoul d
be repl aced.
The Constant Vel oci ty joi nt shoul d al so be
i nspected each ti me the vehi cl e i s servi ced. The CV
joi nt boot i s desi gned to l ast the l i fe of the vehi cl e
and to keep the joi nt l ubri cated. I f grease l eakage or
boot damage i s found, the propel l er shaft must be
repl aced.
PRECAUTIONS
Use the exact repl acement parts when i nstal l i ng
the propel l er shafts. The use of the correct repl ace-
ment parts hel ps to ensure safe operati on. Al l fasten-
ers must be torqued to the speci fi ed val ues for safe
operati on.
Fig. 3 Double Cardan U-Joint
1. LINK YOKE 2. SOCKET SPRING 3. SCOKET BALL RETAINER 4. THRUST WASHER 5. NEEDLE BEARINGS 6. SEAL 7. BEARING CAP 8. REAR SPIDER 9. SOCKET YOKE 10. SOCKET BALL 11. FRONT SPIDER 12. NEEDLE WASHER 13. THRUST WASHER 14. DRIVE SHAFT YOKE 15. RETAINING CLIP
Fig. 4 Constant Velocity Joint
ENCLOSURE CAP JOINT ASSEMBLY PROPELLER SHAFT BOOTCLAMP BOOT BOOT CLAMP
Fig. 5 Maximum Angles And Engine Speed
PROPELLER SHAFT R.P.M. MAX. NORMAL OPERATING ANGLES
Al so make al i gnment reference marks (Fi g. 6) on
the propel l er shaft yoke and axl e, or transmi ssi on,
yoke pri or to servi ci ng. Thi s hel ps to el i mi nate possi -
bl e vi brati on.
CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.
CAUTION: It is very important to protect the exter-
nal machined surface of the slip yoke from damage
during and after propeller shaft removal. If the yoke
is damaged, the transmission extension seal may
be damaged and therefore cause a leak.
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
Refer to Group 22, Ti res and Wheel s, for addi ti onal
i nformati on.
Brake drums that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on. Refer to Group 5,
Brakes, for addi ti onal i nformati on.
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts. Refer to Group 9, Engi nes,
for addi ti onal i nformati on.
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve uni versal
joi nts, or an i ncorrect propel l er shaft angl e, are usu-
al l y the cause of such a vi brati on.
UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180 relative to the yoke may eliminate some
vibrations.
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
PROPELLER SHAFT a. Undercoating or other foreign
material on shaft.
a. Clean exterior of shaft and wash
with solvent.
b. Loose U-joint clamp screws. b. Tighten screws properly.
c. Loose or bent U-joint yoke or
excessive runout.
c. Install replacement yoke.
d. Incorrect drive line angularity. d. Correct angularity.
e. Rear spring center bolt not in
seat.
e. Loosen spring U-bolts and seat
center bolts.
f. Worn U-joint bearings. f. Replace U-joint.
g. Propeller shaft damaged (bent
tube) or out of balance.
g. Install replacement propeller
shaft.
h. Broken rear spring. h. Replace rear spring.
i. Excessive runout or unbalanced
condition.
i. Reindex propeller shaft 180, test
and correct as necessary.
j. Excessive drive pinion gear shaft
yoke runout.
j. Reindex propeller shaft 180and
evaluate.
UNIVERSAL JOINT NOISE a. U-joint clamp screws loose. a. Tighten screws with specified
torque.
b. Lack of lubrication. Replace U-joint.
Fig. 6 Reference Marks on Yokes
REFERENCE MARKS
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90 apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 7).
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 8) and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/4 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 9).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt, and undercoati ng
from the propel l er shaft surface where the di al i ndi -
cator wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
that the effects of the wel d process wi l l not enter i nto
the measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) Repl ace the propel l er shaft i f the runout
exceeds the l i mi t.
Fig. 7 Clamp Screw At Position 1
CLAMP SCREWDRIVER
Fig. 8 Two Clamp Screws At The Same Position
Fig. 9 Clamp Screws Separated
1
2 INCH
RUNOUT SPECIFICATIONS
Front of shaft 0.010 in. (0.25 mm)
Center of shaft 0.015 in. (0.38 mm)
Rear of shaft 0.010 in. (0.25 mm)
NOTE: Measure front/rear runout approximately 3
inches (76 mm) from the weld seam at each end of
the shaft tube for tube lengths over 30 inches. Under
30 inches the max. runout is 0.20 inch for full length
of the tube.
DIAGNOSIS AND TESTING (Continued)
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT PREPARATION
Before measuri ng uni versal joi nt angl es, the fol -
l owi ng must be done;
I nfl ate al l ti res to correct pressure.
Check the angl es i n the same l oaded or
unl oaded condi ti on as when the vi brati on occurred.
Propel l er shaft angl es change accordi ng to the
amount of l oad i n the vehi cl e.
Check the condi ti on of al l suspensi on compo-
nents and veri fy al l fasteners are torqued to speci fi -
cati ons.
Check the condi ti on of the engi ne and transmi s-
si on mounts and veri fy al l fasteners are torqued to
speci fi cati ons.
PROPELLER SHAFT ANGLE MEASUREMENT
To accuratel y check dri vel i ne al i gnment, rai se and
support the vehi cl e at the axl es as l evel as possi bl e.
Al l ow the wheel s and propel l er shaft to turn. Remove
any external beari ng snap ri ngs, i f equi pped, from
uni versal joi nt so that the i ncl i nometer base si ts fl at.
The same basi c procedure apl l i es to both styl es of
front propel l er shafts and the rear propel l er shaft. To
obtai n the front (output) angl e on the CV styl e front
propel l er shaft, the i ncl i nometer i s pl aced on the
machi ned ri ng of the pi ni on fl ange. To obtai n the pro-
pel l er shaft angl e measurement on the CV styl e front
propel l er shaft, the i ncl i nometer i s pl aced on the pro-
pel l er shaft tube.
(1) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng cap i s faci ng downward, i f
necessary.
Always make measurements from front to
rear.
(2) Pl ace I ncl i nometer on yoke beari ng cap, or the
pi ni on fl ange ri ng, (A) paral l el to the shaft (Fi g. 10).
Center bubbl e i n si ght gl ass and record measure-
ment.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).
(3) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng cap, or propel l er shaft
tube on CV styl e propel l er shaft, paral l el to the shaft
(Fi g. 11). Center bubbl e i n si ght gl ass and record
measurement. Thi s measurement can al so be taken
at the rear end of the shaft.
This measurement will give you the propeller
shaft angle (C).
(4) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n transmi ssi on output operati ng angl e.
(5) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng cap paral l el to
the shaft (Fi g. 12). Center bubbl e i n si ght gl ass and
record measurement.
This measurement will give you the pinion
shaft or input yoke angle (B).
(6) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n (Fi g.
13) for addi ti onal i nformati on.
Good cancel l ati on of Ujoi nt operati ng angl es
(wi thi n 1).
Operati ng angl es l ess than 3.
At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
Fig. 10 Front (Output) Angle Measurement(A)
SLIP YOKE BEARING CAP SPECIAL TOOL 7663 (J-23498A)
Fig. 11 Propeller Shaft Angle Measurement(C)
SHAFT YOKE BEARING CAP SPECIAL TOOL 7663 (J23498A)
NOTE: If front propeller shaft must be replaced, the
new shaft length must be measured and adjusted
before the vehicle is returned to use.
REMOVAL
(1) Rai se and support vehi cl e on safety stands.
(2) Shi ft the transmi ssi on and transfer case, i f nec-
essary, i nto the Neutral posi ti on.
(3) Usi ng a sui tabl e marker, mark a l i ne across
the yoke at the transfer case, the l i nk yoke, and pro-
pel l er shaft yoke at the rear of the front propel l er
shaft for i nstal l ati on reference.
(4) Mark a l i ne across the propel l er shaft yoke, or
CV joi nt, and the pi ni on shaft yoke, or pi ni on fl ange,
for i nstal l ati on reference.
CAUTION: Do not loosen lock nut on the CV joint
style propeller shaft or collapse the front propeller
shaft. Driveline vibration can result.
(5) Remove bol ts hol di ng the front uni versal joi nt,
or CV joi nt, to the pi ni on yoke, or fl ange.
(6) Remove bol ts hol di ng rear uni versal joi nt to
the transfer case yoke.
Fig. 13 Universal Joint Angle Example
4.9Angle (C) 3.2Angle (B) Input Yoke Horizontal Level (B) Axle Input Yoke = 3.2 4.9 or (C) Prop. Shaft = 4.9 3.2 Axle Input Operating Angle 1.7 Trans. Output Operating Angle 1.9 Axle Input Operating Angle 1.7 Amount of U-Joint Cancellation 0.2 (A) Output Yoke = 3.0 4.9 or (C) Prop. Shaft = 4.9 3.0 Transmission Output Operating Angle 1.9 3.0Angle (A) Output Yoke
Fig. 12 Rear (Input) Angle Measurement (B)
PINION YOKE BEARING CAP SPECIAL TOOL 7663 (J-23498A)
(7) Separate the rear uni versal joi nt from the
transfer case yoke.
(8) Push rear of propel l er shaft upward to cl ear
transfer case yoke.
(9) Separate front uni versal joi nt, or CV joi nt,
from front axl e.
(10) Separate propel l er shaft from vehi cl e.
INSTALLATION
(1) Posi ti on front propel l er shaft under vehi cl e
wi th rear uni versal joi nt over the transfer case yoke.
(2) Pl ace front uni versal joi nt, or CV joi nt, i nto the
axl e pi ni on yoke, or fl ange. CV joi nt shoul d rotate
freel y i n the pi ni on fl ange.
(3) Al i gn mark on the rear l i nk yoke and uni versal
joi nt to the mark on the transfer case yoke.
(4) Loosel y i nstal l bol ts to hol d uni versal joi nt to
transfer case yoke.
(5) Al i gn mark on front uni versal joi nt, or CV
joi nt, to the mark on the axl e pi ni on yoke, or fl ange.
(6) I nstal l bol ts to hol d front uni versal joi nt, or CV
joi nt, to axl e pi ni on yoke, or fl ange. Ti ghten bol ts to
41 Nm (30 ft. l bs.) for the CV styl e propel l er shaft
and 19 Nm (14 ft. l bs) for the uni versal joi nt styl e
propel l er shaft.
(7) Ti ghten bol ts to hol d uni versal joi nt to transfer
case yoke to 27 Nm (20 ft. l bs.).
(8) Lower vehi cl e and road test to veri fy repai r.
REAR PROPELLER SHAFT
REMOVAL
(1) Rai se and support vehi cl e on safety stands.
(2) Shi ft the transmi ssi on and transfer case, i f nec-
essary, to thei r Neutral posi ti ons.
(3) Usi ng a sui tabl e marker, mark a l i ne across
the axl e pi ni on yoke and the propel l er shaft yoke for
i nstal l ati on reference.
(4) Remove the bol ts hol di ng the uni versal joi nt
cl amps to the pi ni on yoke.
(5) Sl i de the sl i p yoke off of the transmi ssi on, or
transfer case, output shaft and remove the propel l er
shaft (Fi g. 14).
INSTALLATION
(1) Sl i de the sl i p yoke on the transmi ssi on, or
transfer case, output shaft.
(2) Al i gn the i nstal l ati on reference marks made on
the propel l er shaft and pi ni on yoke.
(3) Posi ti on uni versal joi nt i nto pi ni on yoke.
(4) I nstal l the uni versal joi nt cl amp and cl amp
bol ts to the pi ni on yoke. Ti ghten bol ts to 19 Nm (14
ft. l bs.).
SINGLE CARDAN UNIVERSAL JOINT
DISASSEMBLY
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
repl aced as an assembl y.
(1) Remove the propel l er shaft.
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
(3) Remove snap ri ngs from both si des of yoke
(Fi g. 15).
Fig. 14 Rear Propeller Shaft
SLIDING YOKE PROPELLER SHAFTPINIONYOKE CLAMP SCREW 19 Nm (14 ft-lbs) FWD OUTPUT SHAFT
Fig. 15 Remove Snap Ring
SNAP RING
(4) Set the yoke i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the yoke.
(5) Posi ti on the yoke wi th the grease fi tti ng, i f
equi pped, poi nti ng up.
(6) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and press the cap through the yoke to
rel ease the l ower beari ng cap (Fi g. 16).
(7) I f the beari ng cap wi l l not pul l out of the yoke
by hand after pressi ng, tap the yoke ear near the
beari ng cap to di sl odge the cap.
(8) To remove the opposi te beari ng cap, turn the
yoke over and strai ghten the cross i n the open hol e.
Then, careful l y press the end of the cross unti l the
remai ni ng beari ng cap can be removed (Fi g. 17).
CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.
ASSEMBLY
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Posi ti on the cross i n the yoke wi th i ts l ube fi t-
ti ng, i f equi pped, poi nti ng up (Fi g. 18).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 19). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4 to i nstal l the oppo-
si te beari ng cap. I f the joi nt i s sti ff or bi ndi ng, stri ke
the yoke wi th a soft hammer to seat the needl e bear-
i ngs.
(7) Add grease to l ube fi tti ng, i f equi pped.
Fig. 16 Press Out Bearing
PRESS SOCKET
Fig. 17 Press Out Remaining Bearing
CROSS
BEARING CAP
Fig. 18 Install Cross In Yoke
CROSS YOKE
DISASSEMBLY AND ASSEMBLY (Continued)
(8) I nstal l the propel l er shaft.
DOUBLE CARDAN JOINT
DISASSEMBLY
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
repl aced as an assembl y.
(1) Remove the propel l er shaft.
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
(3) Remove al l the beari ng cap snap ri ngs (Fi g. 20).
(4) et the joi nt i n an arbor press or vi se wi th a socket
whose i nsi de di ameter i s l arge enough to recei ve the
beari ng cap posi ti oned beneath the l i nk yoke.
(5) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and parti al l y press one beari ng cap from
the outboard si de of the l i nk yoke enough to grasp
the beari ng cap wi th vi se jaws (Fi g. 21). Be sure to
remove grease fi tti ngs that i nterfere wi th removal .
(6) Grasp the protrudi ng beari ng by vi se jaws. Tap
the l i nk yoke wi th a mal l et and dri ft to di sl odge the
beari ng cap from the yoke (Fi g. 22).
Fig. 19 Install Bearing On Trunnion
BEARING CAP
TRUNNION
Fig. 20 Remove Snap Rings
Fig. 21 Press Out Bearing
Fig. 22 Remove Bearing From Yoke
(7) Fl i p assembl y and repeat Step 4, Step 5, and
Step 6 to remove the opposi te beari ng cap. Thi s wi l l
then al l ow removal of the cross centeri ng ki t assem-
bl y and spri ng (Fi g. 23).
(8) Press the remai ni ng beari ng caps out the other
end of the l i nk yoke as descri bed above to compl ete
the di sassembl y.
ASSEMBLY
During assembly, ensure that the alignment
marks on the link yoke and propeller shaft
yoke are aligned.
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Fi t a cross i nto the propel l er shaft yoke (Fi g. 24).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 25). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng (Fi g. 26).
(5) I nstal l a snap ri ng.
Fig. 23 Remove Centering Kit
Fig. 24 Install Cross In Yoke
Fig. 25 Install Bearing Cap
Fig. 26 Press In Bearing Cap
(6) Fl i p the propel l er shaft yoke and i nstal l the
beari ng cap onto the opposi te trunni on. I nstal l a
snap ri ng (Fi g. 27).
(7) Fi t the l i nk yoke on the remai ni ng two trun-
ni ons and press both beari ng caps i nto pl ace (Fi g.
28).
(8) I nstal l snap ri ngs.
(9) I nstal l the centeri ng ki t assembl y i nsi de the
l i nk yoke maki ng sure the spri ng i s properl y posi -
ti oned (Fi g. 29).
(10) Pl ace two beari ng caps on opposi te trunni ons
of the remai ni ng cross. Fi t the open trunni ons i nto
the l i nk yoke bores and the beari ng caps i nto the
centeri ng ki t (Fi g. 30).
Fig. 28 Install Link Yoke
Fig. 29 Install Centering Kit
Fig. 30 Install Remaining Cross
(11) Press the remai ni ng two beari ng caps i nto
pl ace and i nstal l snap ri ngs (Fi g. 31).
(12) Tap the snap ri ngs to al l ow them to seat i nto
the grooves (Fi g. 32).
(13) Check for proper assembl y. Fl ex the joi nt
beyond center, i t shoul d snap over-center i n both
di recti ons when correctl y assembl ed (Fi g. 33).
(14) I nstal l the propel l er shaft.
SINGLE AND DOUBLE CARDAN JOINT
(1) Cl ean al l the uni versal joi nt yoke bores wi th
cl eani ng sol vent and a wi re brush.
(2) I nspect the yokes for di storti on, cracks, and
worn beari ng cap bores.
ADJ USTMENTS
FRONT PROPELLER SHAFT MEASUREMENT
NOTE: A propeller shaft that has been in use for a
long period of time cannot be adjusted. If the length
of the propeller is incorrect and causing vibration,
replace the propeller shaft.
Thi s measurement i s onl y necessary for the CV
styl e propel l er shaft and i s to be taken wi th the shaft
i nstal l ed and the vehi cl e at proper ri de hei ght.
(1) Pl ace vehi cl e on fl oor or dri ve-on hoi st wi th ful l
wei ght of vehi cl e on suspensi on.
(2) Measure the di stance from the face of the CV
joi nt cup to the end of the CV joi nt boot (Fi g. 34).
(3) Loosen the l ock nut and adjust the di stance by
movi ng the end of the shaft i n or out of the other
end.
(4) When the shaft i s adjusted to the correct
l ength of 142.7 mm (5.61 i n.), ti ghten the l ock-nut
(Fi g. 35) to 115 Nm (85 ft. l bs.).
AXLE PINION ANGLE ADJUSTMENT
The pi ni on angl e of the front axl e can be adjusted
by the use of adjustment cams i n the l ower suspen-
si on arms (Fi g. 36). The pri mary functi on for the
Fig. 32 Seat Snap Rings In Groove
Fig. 33 Check Assembl y
cams i s to adjust the caster angl e for the al i gnment
of the front suspensi on. When usi ng the cams to
adjust the pi ni on angl e, make sure that both cams
are moved equal l y. After the pi ni on angl e i s adjusted,
the front suspensi on al i gnment shoul d be checked to
ensure that si de-to-si de caster angl es vari ance i s
wi th-i n the acceptabl e range. Havi ng the correct pi n-
i on angl e does have pri ori ty over havi ng the pre-
ferred caster angl e.
A cam ki t i s avai l abl e to be i nstal l ed i n the rear
axl e l ower suspensi on arms i n order to provi de
adjustabl i ty of the pi ni on angl e. Fol l ow the proce-
dures suppl i ed wi th the ki t i n order to ensure a safe
i nstal l ati on.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Front Propeller Shaft
Bolts, Rear Yoke . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Bolts, Front Yoke . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Nut, Lock . . . . . . . . . . . . . . . . 115 Nm (85 ft. l bs.)
Rear Propeller Shaft
Bolts, Rear Yoke . . . . . . . . . . . 19 Nm (14 ft. l bs.)
SPECIAL TOOLS
PROPELLER SHAFT
Fig. 34 Measurement
CV JOINT CUP CV BOOT END MEASUREMENT
Fig. 35 Locknut
CONSTANT VELOCITY JOINT AXLE FLANGE BOLTS DOUBLE CARDAN JOINT FRONT DRIVE SHAFT LOCK NUT BOOT
Fig. 36 Adjustment Cam
ADJUSTMENT CAM AXLE BRACKET BRACKET REIN- FORCEMENT LOWER SUSPENSION ARM
Inclinometer7663
ADJ USTMENTS (Continued)
181 FBI AXLE
INDEX
page page
GENERAL INFORMATION
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . 15
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 16
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . 17
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . 17
FRONT AXLES . . . . . . . . . . . . . . . . . . . . . . . . . 18
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL INFORMATION . . . . . . . . . . . . . . . . 16
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . 17
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . 20
AXLE BUSHING REPLACEMENT . . . . . . . . . . . 30
AXLE CONSTANTVELOCITY (C/V) JOINT
BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 32
AXLE SHAFTCARDAN U-JOINT . . . . . . . . . . 21
COLLAPSIBLE SPACER . . . . . . . . . . . . . . . . . . 24
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . 31
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 30
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . 20
HUB BEARING AND AXLE SHAFT . . . . . . . . . . 27
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 32
PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . 23
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
STEERING KNUCKLE AND BALL STUDS . . . . 28
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 38
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . 38
CARDAN U-JOINT . . . . . . . . . . . . . . . . . . . . . . 38
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 41
GEAR CONTACT PATTERN ANALYSIS . . . . . . 44
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 39
SPECIFICATIONS
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 44
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SPECIAL TOOLS
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 46
GENERAL INFORMATION
181 FBI AXLE
The 181 Front Beam-desi gn I ron (FBI ) axl e con-
si sts of a cast i ron di fferenti al housi ng wi th axl e
shaft tubes extendi ng from ei ther si de. The tubes are
pressed i nto the di fferenti al housi ng and wel ded.
The i ntegral type housi ng, hypoi d gear desi gn has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear.
The axl e has a fi tti ng for a vent hose used to
rel i eve i nternal pressure caused by l ubri cant vapor-
i zati on and i nternal expansi on.
The axl es are equi pped wi th semi fl oati ng axl e
shafts, meani ng that l oads are supported by the hub
beari ngs. The axl e shafts are retai ned by nuts at the
hub beari ngs. The hub beari ngs are bol ted to the
steeri ng knuckl e at the outboard end of the axl e tube
yoke. The hub beari ngs are servi ced as an assembl y.
For vehi cl es wi th ABS brakes, the ABS wheel
speed sensors are attached to the knuckl e assem-
bl i es. The tone ri ngs for the ABS system are pressed
onto the axl e shaft. Do not damage ABS tone
wheel or the sensor when removing axle shafts.
The stamped steel cover provi des a means for
i nspecti on and servi ci ng the di fferenti al .
The 181 FBI axl e has the assembl y part number
and gear rati o l i sted on a tag. The tag i s attached to
the housi ng cover by a cover bol t. Bui l d date i denti -
fi cati on codes are stamped on the cover si de of the
axl e shaft tube.
The di fferenti al case i s a onepi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a rol l
pi n. Di fferenti al beari ng prel oad and ri ng gear back-
l ash i s adjusted by the use of shi ms (sel ect thi ck-
ness). The shi ms are l ocated between the di fferenti al
beari ng cones and case. Pi ni on beari ng prel oad i s set
and mai ntai ned by the use of a col l apsi bl e spacer.
LUBRICANT SPECIFICATIONS
A mul ti purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
The l ubri cant shoul d have MI LL2105C and
API GL 5 qual i ty speci fi cati ons.
Lubri cant i s a thermal l y stabl e SAE 80W90
gear l ubri cant.
Lubri cant for axl es i ntended for heavy-duty or
trai l er tow use i s SAE 75W140 SYNTHETI C gear
l ubri cant.
The 181 FBI axl e l ubri cant capaci ty i s 1.2 L (2.5
pts.).
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
STANDARD DIFFERENTIAL
The di fferenti al gear system di vi des the torque
between the axl e shafts. I t al l ows the axl e shafts to
rotate at di fferent speeds when turni ng corners.
Each di fferenti al si de gear i s spl i ned to an axl e
shaft. The pi ni on gears are mounted on a pi ni on
mate shaft and are free to rotate on the shaft. The
pi ni on gear i s fi tted i n a bore i n the di fferenti al case
and i s posi ti oned at a ri ght angl e to the axl e shafts.
I n operati on, power fl ow occurs as fol l ows:
The pi ni on gear rotates the ri ng gear
The ri ng gear (bol ted to the di fferenti al case)
rotates the case
The di fferenti al pi ni on gears (mounted on the
pi ni on mate shaft i n the case) rotate the si de gears
The si de gears (spl i ned to the axl e shafts) rotate
the shafts
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
GENERAL INFORMATION
Axl e beari ng probl em condi ti ons are usual l y caused
by:
I nsuffi ci ent or i ncorrect l ubri cant.
Forei gn matter/water contami nati on.
I ncorrect beari ng prel oad torque adjustment.
I ncorrect backl ash.
Axl e gear probl em condi ti ons are usual l y the resul t
of:
I nsuffi ci ent l ubri cati on.
I ncorrect or contami nated l ubri cant.
Overl oadi ng (excessi ve engi ne torque) or exceed-
i ng vehi cl e wei ght capaci ty.
I ncorrect cl earance or backl ash adjustment.
Axl e component breakage i s most often the resul t
of:
Severe overl oadi ng.
I nsuffi ci ent l ubri cant.
I ncorrect l ubri cant.
I mproperl y ti ghtened components.
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, or worn/dam-
aged gears.
Gear noi se usual l y happens at a speci fi c speed
range. The range i s 30 to 40 mph, or above 50 mph.
The noi se can al so occur duri ng a speci fi c type of
Fig. 1 Differential OperationStraightAhead Driving
IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED PINION GEAR SIDE GEAR PINION GEARS ROTATE WITH CASE
Fig. 2 Differential OperationOn Turns
AXLE
OUTER WHEEL 110% CASE
SPEED
100% DIFFERENTIAL CASE SPEED
INNER WHEEL 90% CASE
SPEED
PINION GEARS ROTATE ON PINION SHAFT
dri vi ng condi ti on. These condi ti ons are accel erati on,
decel erati on, coast, or constant l oad.
When road testi ng, accel erate the vehi cl e to the
speed range where the noi se i s the greatest. Shi ft
out-of-gear and coast through the peaknoi se range.
I f the noi se stops or changes greatl y:
Check for i nsuffi ci ent l ubri cant.
I ncorrect ri ng gear backl ash.
Gear damage.
Di fferenti al si de and pi ni on gears can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ghtahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on gear mate shaft can al so
cause a snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on gear bear-
i ngs can al l produce noi se when worn or damaged.
Beari ng noi se can be ei ther a whi ni ng, or a growl i ng
sound.
Pi ni on gear beari ngs have a constantpi tch noi se.
Thi s noi se changes onl y wi th vehi cl e speed. Pi ni on
beari ng noi se wi l l be hi gher because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
Ujoi nt or by worn si degear thrust washers. A worn
pi ni on gear shaft bore wi l l al so cause l ow speed
knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
Damaged dri ve shaft.
Mi ssi ng dri ve shaft bal ance wei ght(s).
Worn or outofbal ance wheel s.
Loose wheel l ug nuts.
Worn Ujoi nt(s).
Loose/broken spri ngs.
Damaged axl e shaft beari ng(s).
Loose pi ni on gear nut.
Excessi ve pi ni on yoke run out.
Bent axl e shaft(s).
Check for l oose or damaged frontend components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rearend
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
Refer to Group 22, Wheel s and Ti res, for addi ti onal
vi brati on i nformati on.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
Hi gh engi ne i dl e speed
Loose engi ne/transmi ssi on/transfer case mounts
Worn Ujoi nts
Loose spri ng mounts
Loose pi ni on gear nut and yoke
Excessi ve ri ng gear backl ash
Excessi ve si de gear/case cl earance
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
FRONT AXLES
DIAGNOSIS
WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must be
replaced.
AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1. Inspect axle shaft tube alignment. Correct as
necessary.
2. Bent or sprung axle shaft. 2. Replace bent or sprung axle shaft.
3. End play in drive pinion bearings. 3. Refer to Drive Pinion Bearing Pre-Load
Adjustment.
4. Excessive gear backlash between ring gear
and pinion gear.
4. Check adjustment of ring gear backlash and
pinion gear. Correct as necessary.
5. Improper adjustment of drive pinion gear
shaft bearings.
5. Adjust drive pinion shaft bearings.
6. Loose drive pinion gearshaft yoke nut. 6. Tighten drive pinion gearshaft yoke nut with
specified torque.
7. Improper wheel bearing adjustment. 7. Readjust as necessary.
8. Scuffed gear tooth contact surfaces. 8. If necessary, replace scuffed gears.
AXLE SHAFT BROKE 1. Misaligned axle shaft tube. 1. Replace broken axle shaft after correcting
axle shaft tube alignment.
2. Vehicle overloaded. 2. Replace broken axle shaft. Avoid excessive
weight on vehicle.
3. Erratic clutch operation. 3. Replace broken axle shaft after inspecting for
other possible casues. Avoid erratic use of
clutch.
4. Grabbing clutch. 4. Replace broken axle shaft. Inspect clutch and
make necessary repairs or adjustments.
DIFFERENTIAL CASE
CRACKED
1. Improper adjustment of differential bearings. 1. Replace cracked case; examine gears and
bearings for possible damage. At reassembly,
adjust differential bearings properly.
2. Excessive ring gear backlash. 2. Replace cracked case; examine gears and
adjust ring gear backlash properly.
3. Vehicle overloaded. 3. Replace cracked case; examine gears and
bearings for possible damage. Avoid excessive
weight on vehicle.
4. Erratic clutch operation. 4. Replace cracked case. After inspecting for
other possible causes, examine gears and
bearings for possible damage. Avoid erratic use
of clutch.
DIFFERENTIAL GEARS
SCORED
1. Insufficient lubrication. 1. Replace scored gears. Scoring marks on the
drive face of gear teeth or in the bore are
caused by instantaneous fusing of the mating
surfaces. Scored gears should be replaced. Fill
rear differential housing to required capacity
with proper lubricant. Refer to Specifications.
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all gears and
bearings for possible damage. Clean and refill
differential housing to required capacity with
proper lubricant.
3. Excessive spinning of one wheel/tire. 3. Replace scored gears. Inspect all gears,
pinion bores and shaft for damage. Service as
necessary.
LOSS OF LUBRICANT 1. Lubricant level too high. 1. Drain excess lubricant by removing fill plug
and allow lubricant to level at lower edge of fill
plug hole.
CONTINUED
LOSS OF LUBRICANT 2. Worn axle shaft seals. Replace worn seals.
3. Cracked differential housing. 3. Repair or replace housing as
necessary.
4. Worn drive pinion gear shaft
seal.
4. Replace worn drive pinion gear
shaft seal.
5. Scored and worn yoke. 5. Replace worn or scored yoke and
seal.
6. Axle cover not properly sealed. 6. Remove cover and clean flange
and reseal.
AXLE OVERHEATING 1. Lubricant level too low. 1. Refill differential housing.
2. Incorrect grade of lubricant. 2. Drain, flush and refill with correct
amount of the correct lubricant.
3. Bearings adjusted too tight. 3. Readjust bearings.
4. Excessive gear wear. 4. Inspect gears for excessive wear
or scoring. Replace as necessary.
5. Insufficient ring gear backlash. 5. Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (RING
GEAR AND PINION)
1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for possible
damage. Avoid erratic clutch
operation.
3. Ice-spotted pavements. 3. Replace gears. Examine the
damage. Replace parts as required.
4. Improper adjustments. 4. Replace gears. Examine other
parts for possible damage. Ensure
ring gear backlash is correct.
AXLE NOISE 1. Insufficient lubricant. 1. Refill axle with correct amount of
proper lubricant. Also inspect for
leaks and correct as necessary.
2. Improper ring gear and drive
pinion gear adjustment.
2. Check ring gear and pinion gear
teeth contact pattern.
3. Unmatched ring gear and drive
pinion gear.
3. Remove unmatched ring gear
and drive pinion gear. Replace with
matched gear and drive pinion gear
set.
4. Worn teeth on ring gear or drive
pinion gear.
4. Check teeth on ring gear and
drive pinion gear for correct contact.
If necessary, replace with new
matched set.
5. Loose drive pinion gear shaft
bearings.
5. Adjust drive pinion gearshaft
bearing preload torque.
6. Loose differential bearings. 6. Adjust differential bearing preload
torque.
7. Misaligned or sprung ring gear. 7. Measure ring gear runout.
8. Loose differential bearing cap
bolts.
8. Tighten with specified torque.
SERVICE PROCEDURES
LUBRICANT CHANGE
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
drai n the l ubri cant from the housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the seal ant from the housi ng and cover
surfaces. Use sol vent to cl ean the mati ng surfaces.
(6) Appl y a bead of Mopar Si l i cone Rubber Seal -
ant, or equi val ent, to the housi ng cover (Fi g. 3).
Install the housing cover within 5 minutes
after applying the sealant.
(7) I nstal l the cover and any i denti fi cati on tag.
Ti ghten the cover bol ts i n a cri sscross pattern to 41
Nm (30 ft. l bs.) torque.
(8) Refi l l the di fferenti al wi th Mopar Hypoi d
Gear Lubri cant, or equi val ent, to bottom of the fi l l
pl ug hol e. Refer to the Lubri cant Speci fi cati ons i n
thi s group for the quanti ty necessary.
(9) I nstal l the fi l l hol e pl ug and l ower the vehi cl e.
DRIVE AXLE ASSEMBLY
REMOVAL
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove the wheel s and ti res.
(5) Remove the brake rotors and cal i pers from the
axl e. Refer to Group 5, Brakes, for proper procedures.
(6) Di sconnect the wheel sensor wi ri ng harness
from the vehi cl e wi ri ng harness, i f necessary.
(7) Di sconnect the vent hose from the axl e shaft
tube.
(8) Mark the propel l er shaft and yoke, or pi ni on
fl ange, for i nstal l ati on al i gnment reference.
(9) Remove propel l er shaft.
(10) Di sconnect stabi l i zer bar l i nks at the axl e.
(11) Di sconnect shock absorbers from axl e brack-
ets.
(12) Di sconnect track bar.
(13) Di sconnect the ti e rod and drag l i nk from the
steeri ng knuckl e. Refer to Group 2, Suspensi on, for
proper procedures.
(14) Di sconnect the steeri ng damper from the axl e
bracket.
(15) Di sconnect the upper and l ower suspensi on
arms from the axl e brackets.
(16) Lower the l i fti ng devi ce enough to remove the
axl e. The coi l spri ngs wi l l drop wi th the axl e.
(17) Remove the coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, ride height and
handling could be affected.
(1) I nstal l the spri ngs and retai ner cl i ps. Ti ghten
the retai ner bol ts to 21 Nm (16 ft. l bs.) torque.
(2) Support the axl e on a sui tabl e l i fti ng devi ce
and posi ti on axl e under the vehi cl e.
(3) Rai se the axl e and al i gn i t wi th the spri ng
pads.
(4) Posi ti on the upper and l ower suspensi on arms
i n the axl e brackets. Loosel y i nstal l bol ts and nuts to
hol d suspensi on arms to the axl e brackets.
(5) Connect the vent hose to the axl e shaft tube.
(6) Connect the track bar to the axl e bracket.
Loosel y i nstal l the bol t to hol d the track bar to the
axl e bracket.
(7) I nstal l the shock absorbers and ti ghten the
bol ts to 23 Nm (17 ft. l bs.) torque.
Fig. 3 Typical Housing Cover With Sealant
SEALING SURFACE CONTOUR OF BEAD BEAD THICK- NESS 6.35MM (1/4)
(8) I nstal l the stabi l i zer bar l i nks to the axl e
brackets. Ti ghten the nut to 95 Nm (70 ft. l bs.)
torque.
(9) I nstal l the drag l i nk and ti e rod to the steeri ng
knuckl es. Refer to Group 2, Suspensi on, for proper
procedures.
(10) I nstal l the steeri ng damper to the axl e
bracket and ti ghten the nut to 75 Nm (55 ft. l bs.)
torque.
(11) I nstal l the brake rotors and cal i pers. Refer to
Group 5, Brakes, for the proper procedures.
(12) Connect the wheel speed sensor wi ri ng har-
ness to the vehi cl e wi ri ng harness, i f necessary.
(13) Al i gn the previ ousl y made marks on the pro-
pel l er shaft and the yoke, or pi ni on fl ange.
(14) I nstal l the bol ts to hol d the propel l er shaft to
the pi ni on fl ange, i f equi pped.
(15) I nstal l the straps and bol ts to hol d the propel -
l er shaft to the yoke, i f equi pped.
(16) Check and fi l l axl e l ubri cant. Refer to the
Lubri cant Speci fi cati ons i n thi s group for the quan-
ti ty necessary.
(17) I nstal l the wheel and ti re assembl i es.
(18) Remove the l i fti ng devi ce from the axl e and
l ower the vehi cl e.
Nm (55 ft. l bs.) torque. Ti ghten the l ower suspensi on
arm nuts to 115 Nm (85 ft. l bs.) torque.
(20) Ti ghten the track bar bol t at the axl e bracket
to 100 Nm (74 ft. l bs.) torque.
(21) Check the front wheel al i gnment.
AXLE SHAFT CARDAN U-JOINT
Si ngl e cardan Ujoi nt components are not servi ce-
abl e. I f defecti ve, they must be repl aced as a uni t. I f
the beari ngs, seal s, spi der, or beari ng caps are dam-
aged or worn, repl ace the compl ete Ujoi nt.
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Also, to avoid distorting the
yoke, do not over tighten the vise jaws.
(1) Remove axl e shaft.
(2) Remove the beari ng cap retai ni ng snap ri ngs
(Fi g. 4).
It can be helpful to saturate the bearing caps
with penetrating oil prior to removal.
(3) Locate a socket where the i nsi de di ameter i s
l arger i n di ameter than the beari ng cap. Pl ace the
socket (recei ver) agai nst the yoke and around the
peri meter of the beari ng cap to be removed.
(4) Locate a socket where the outsi de di ameter i s
smal l er i n di ameter than the beari ng cap. Pl ace the
socket (dri ver) agai nst the opposi te beari ng cap.
(5) Posi ti on the yoke wi th the sockets i n a vi se
(Fi g. 5).
(6) Compress the vi se jaws to force the beari ng cap
i nto the l arger socket (recei ver).
(7) Rel ease the vi se jaws. Remove the sockets and
beari ng cap that was parti al l y forced out of the yoke.
(8) Repeat the above procedure for the remai ni ng
beari ng cap.
(9) Remove the remai ni ng beari ng cap, beari ngs,
seal s and spi der from the propel l er shaft yoke.
Fig. 4 Axle Shaft Outer UJoint
SHAFT YOKE BEARING CAP SNAP RINGS BEARING CAP SPINDLE YOKE BEARING BEARING CAP SNAP RINGS BEARING CAP
Fig. 5 Yoke Bearing Cap Removal
LARGE-DIAMETER SOCKET WRENCH VISE SMALL-DIAMETER SOCKET WRENCH
INSTALLATION
(1) Pack the beari ng caps 1/3 ful l of wheel beari ng
l ubri cant. Appl y extreme pressure (EP), l i thi umbase
l ubri cant to ai d i n i nstal l ati on.
(2) Posi ti on the spi der i n the yoke. I nsert the seal s
and beari ngs. Tap the beari ng caps i nto the yoke
bores far enough to hol d the spi der i n posi ti on.
(3) Pl ace the socket (dri ver) agai nst one beari ng
cap. Posi ti on the yoke wi th the socket wrench i n a
vi se.
(4) Compress the vi se to force the beari ng caps
i nto the yoke. Force the caps enough to i nstal l the
retai ni ng cl i ps.
(5) I nstal l the beari ng cap retai ni ng cl i ps.
(6) I nstal l axl e shaft.
AXLE CONSTANTVELOCITY (C/V) JOINT BOOT
The only service procedure to be performed
on the axle C/V joint, is the replacement of the
joint seal boot. I f any fai l ure of i nternal axl e shaft
components i s di agnosed duri ng a vehi cl e road test,
the axl e shaft must be repl aced as an assembl y.
REMOVAL
(1) Remove axl e shaft.
(2) Remove l arge boot cl amp retai ni ng C/V joi nt
seal i ng boot, to C/V joi nt housi ng and di scard.
(3) Remove smal l cl amp that retai ns outer C/V
joi nt seal i ng boot to axl e shaft and di scard (Fi g. 6).
(4) Remove seal i ng boot from outer C/V joi nt hous-
i ng and sl i de i t down and off the axl e shaft.
(5) Thoroughl y cl ean and i nspect axl e C/V joi nt
assembl y and axl e shaft for any si gns of excessi ve
wear. If any parts show signs of excessive wear,
the axle shaft assembly will require replace-
ment. Component parts of these axle shaft
assemblies are not serviceable.
INSTALLATION
(1) Sl i de new seal i ng boot l arge cl amp over axl e
shaft and onto C/V joi nt.
(2) Sl i de the axl e C/V joi nt seal i ng boot onto the
axl e shaft.
(3) Di stri bute 1/2 the amount of grease provi ded i n
seal boot servi ce package (DO NOT USE ANY
OTHER TYPE OF GREASE) i nto axl e C/V joi nt
assembl y housi ng. Put the remai ni ng amount i nto
the seal i ng boot.
(4) I nstal l axl e C/V joi nt boot smal l cl amp evenl y
on seal i ng boot.
(5) Posi ti on axl e C/V joi nt boot i nto retai ni ng
groove i n axl e C/V joi nt housi ng. Then, i nstal l l arge
retai ni ng cl amp evenl y on seal i ng boot.
(6) Cl amp smal l seal i ng boot cl amp onto axl e shaft
usi ng Cri mper C-4975-A. Pl ace cri mpi ng tool
C-4975-A over bri dge of cl amp (Fi g. 7).
(7) Ti ghten nut on cri mpi ng tool C-4975-A unti l
jaws on tool are cl osed compl etel y together, face to
face (Fi g. 8).
Fig. 6 Outer C/V Joint Seal Boot Clamps
AXLE C/V JOINT HOUSING
LARGE CLAMP
AXLE SHAFT
Fig. 7 Crimping Tool Installed On BootClamp
SPECIAL TOOL C-4975A
AXLE SHAFT
Fig. 8 Sealing Boot Retaining Clamp Installed
CLAMP
JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE
CAUTION: Seal must not be dimpled, stretched or
out of shape in any way. If seal is NOT shaped cor-
rectly, equalize pressure in seal and shape it by
hand.
(8) Cl amp l arge seal i ng boot cl amp onto axl e shaft
usi ng Cri mper C-4975-A. Pl ace cri mpi ng tool
C-4975-A over bri dge of cl amp (Fi g. 9).
(9) Ti ghten nut on cri mpi ng tool C-4975-A unti l
jaws on tool are cl osed compl etel y together, face to
face.
PINION SHAFT SEAL
REMOVAL
(2) Remove wheel and ti re assembl i es.
(3) Remove brake rotors and cal i pers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke, or
pi ni on fl ange, for i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke, or
pi ni on fl ange.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Usi ng a short pi ece of pi pe and Hol der 6958 to
hol d the pi ni on yoke, or pi ni on fl ange, remove the
pi ni on nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pi ni on yoke, or pi ni on fl ange, (Fi g. 10).
(10) Use Remover 7794-A and sl i de hammer to
remove the pi ni on shaft seal (Fi g. 11).
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C-4171 (Fi g. 12).
(2) I nstal l yoke, or pi ni on fl ange, on the pi ni on
gear wi th I nstal l er W-162D, Cup 8109, and Hol der
6958 (Fi g. 13).
Fig. 9 Crimping Tool Installed On LargeBoot Clamp
SPECIAL TOOL C-4975A SEALING BOOT OUTER C/V JOINT BOOT CLAMP
Fig. 10 Pinion Yoke Removal
SPECIAL TOOL C-3281 YOKE SPECIAL TOOL C-452
Fig. 11 Seal Removal
SPECIAL TOOL 7794A SLIDE HAMMER PINION SEAL
Fig. 12 Pinion Seal Installation
SPECIAL TOOL C-4171
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bear-
ings may result.
(3) I nstal l the pi ni on washer and a new nut on the
pi ni on gear. Tighten the nut only enough to
remove the shaft end play.
(4) Rotate the pi ni on shaft usi ng a (i n. l bs.) torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal , pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 14).
(5) I f the rotati ng torque i s l ow, use Hol der 6958 to
hol d the pi ni on yoke (Fi g. 15), and ti ghten the pi ni on
shaft nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l
proper rotati ng torque i s achi eved.
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
(6) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and yoke, or pi ni on fl ange, and i nstal l
the propel l er shaft.
(7) Check and fi l l the gear l ubri cant. Refer to the
Lubri cant Speci fi cati ons for gear l ubri cant requi re-
ments.
(9) I nstal l wheel and ti re assembl i es.
COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
pi ni on fl ange.
Fig. 13 Pinion Yoke Installation
PINION YOKE
AXLE HOUSING
Fig. 14 Check Pinion Rotation Torque
PINION YOKE INCH POUND TORQUE WRENCH
Fig. 15 Tightening Pinion Shaft Nut
PINION FLANGE FRONTAXLE TOOL 6958
l ati on reference.
hol d the pi ni on yoke, or pi ni on fl ange, remove the
pi ni on nut and washer.
remove the pi ni on yoke, or fl ange, (Fi g. 16).
(11) Remove the front pi ni on beari ng usi ng a pai r
of sui tabl e pi ck tool s to pul l the beari ng strai ght off
the pi ni on gear shaft. I t may be necessary to l i ghtl y
tap the end of the pi ni on gear wi th a rawhi de or rub-
ber mal l et i f the beari ng becomes bound on the pi n-
i on shaft.
(12) Remove the col l apsi bl e spacer.
REMOVAL W/PINION REMOVED
pi ni on fl ange.
l ati on reference.
(8) Remove di fferenti al assembl y from axl e hous-
i ng.
(9) Usi ng Hol der 6958 to hol d yoke, or fl ange, and
a short l ength of 1 i n. pi pe, remove the pi ni on nut
and washer.
(10) Usi ng Remover C-452 and Wrench C-3281,
remove the pi ni on yoke, or fl ange, from pi ni on shaft
(Fi g. 16).
(11) Remove the pi ni on gear from housi ng (Fi g.
18). Catch the pi ni on wi th your hand to prevent i t
from fal l i ng and bei ng damaged.
(12) Remove col l apsi bl e spacer from pi ni on shaft.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft (Fi g. 19).
(2) I f pi ni on gear was removed, i nstal l pi ni on gear
i n housi ng.
(3) I nstal l pi ni on front beari ng, i f necessary.
and Handl e C-4171 (Fi g. 20), i f necessary.
(5) I nstal l yoke, or pi ni on fl ange, wi th I nstal l er
W-162-D, Cup 8109, and hol der 6958 (Fi g. 21).
Fig. 18 Remove Pinion Gear
RAWHIDE HAM- MER
(6) I f the ori gi nal pi ni on beari ngs are bei ng used,
i nstal l di fferenti al assembl y and axl e shafts, i f neces-
sary.
NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
pi ni on gear. Ti ghten the nut to 217 Nm (160 ft. l bs.)
mi ni mum. Do not overtighten. Maxi mum torque
i s 353 Nm (260 ft. l bs.).
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
NOTE: If the spacer requires more than 353 Nm
(260 ft. lbs.) of torque to crush, the collapsible
spacer is defective and must be replaced.
(8) Usi ng yoke hol der 6958, a short l ength of 1 i n.
pi pe, and a torque wrench set at 353 Nm (260 ft.
l bs.), crush col l apsi bl e spacer unti l beari ng end pl ay
i s taken up (Fi g. 22).
Fig. 19 Collapsible Preload Spacer
COLLAPS- IBLESPACER SHOULDER PINIONGEAR OIL SLINGER REAR BEAR- ING
SPECIAL TOOL C-4171
PINION YOKE
AXLE HOUSING
Fig. 22 Tightening Pinion Nut
(9) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l the rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over
crushi ng the col l apsi bl e spacer (Fi g. 23).
(10) Check rotati ng torque wi th an i nch pound
torque wrench (Fi g. 23). The torque necessary to
rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs The readi ng recorded dur-
i ng removal , pl us an addi ti onal 0.56 Nm (5 i n. l bs.).
New Beari ngs 2 to 5 Nm (15 to 35 i n. l bs.).
(11) I nstal l di fferenti al assembl y and axl e shafts, i f
necessary.
(12) Al i gn marks made previ ousl y on yoke, or pi n-
i on fl ange, and propel l er shaft and i nstal l propel l er
shaft.
(13) I nstal l brake rotors and cal i pers. Refer to
(14) Add gear l ubri cant, i f necessary. Refer to
Lubri cant Speci fi cati ons of thi s secti on for l ubri cant
requi rements.
(16) Lower vehi cl e.
HUB BEARING AND AXLE SHAFT
I f the axl e shaft and hub beari ng are bei ng
removed i n order to servi ce another component, the
axl e shaft and hub beari ng can be removed as an
assembl y.
REMOVAL
(3) Remove the brake cal i per and rotor. Refer to
(4) Remove ABS wheel speed sensor, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(5) Remove the cotter pi n, nut retai ner, and axl e
hub nut (Fi g. 24), i f necessary.
(6) Remove the hub to knuckl e bol ts (Fi g. 25).
(7) Remove the hub from the steeri ng knuckl e and
axl e shaft, i f necessary.
Fig. 23 Check Pinion Gear Rotation TorqueTypical
Fig. 24 Hub, Knuckle and Axle Shaft
BRAKE SHIELD WASHER RETAINER COTTER PIN NUT HUB AND BEARING ASSEMBLY STEERING KNUCKLE BOLT TONE WHEEL (ABS)
(8) Remove hub beari ng and axl e shaft assembl y
(Fi g. 26), or axl e shaft from axl e. Avoid damaging
the axle shaft oil seals in the axle housing.
(9) Remove the brake rotor shi el d from the hub
beari ng or knuckl e (Fi g. 24).
INSTALLATION
(1) Thoroughl y cl ean the axl e shaft (Fi g. 24) and
appl y a thi n fi l m of Mopar Wheel Beari ng Grease,
or equi val ent, to the shaft spl i nes, seal contact sur-
face, and hub bore.
(2) I nstal l the brake rotor shi el d to the knuckl e.
(3) I nstal l the hub beari ng and axl e shaft assem-
bl y, or axl e shaft, i nto the housi ng and di fferenti al
si de gears. Avoi d damagi ng the axl e shaft oi l seal s i n
the axl e housi ng.
(4) I nstal l the hub beari ng, i f necessary.
102 Nm (75 ft. l bs.) torque.
(6) I nstal l the hub washer and nut, i f necessary.
Ti ghten the hub nut to 237 Nm (175 ft. l bs.) torque.
I nstal l the nut retai ner and a new cotter pi n (Fi g.
24).
(7) I nstal l ABS wheel speed sensor, i f necessary.
(8) I nstal l the brake rotor and cal i per. Refer to
STEERING KNUCKLE AND BALL STUDS
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. Removal and
i nstal l ati on of upper and l ower bal l studs requi re the
use of Tool Ki t 6289.
KNUCKLE REMOVAL
(1) Remove hub beari ng and axl e shaft.
(2) Di sconnect the ti e-rod or drag l i nk from the
steeri ng knuckl e arm. Refer to Group 2, Suspensi on,
for proper procedures.
(3) Remove the cotter pi ns from the upper and
l ower bal l studs.
(4) Remove the upper and l ower bal l stud nuts.
(5) Stri ke the steeri ng knuckl e wi th a brass ham-
mer to l oosen knuckl e from the bal l studs. Remove
knuckl e from bal l studs (Fi g. 27).
UPPER BALL STUD REPLACEMENT
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 28).
LOWER BALL STUD REPLACEMENT
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 29).
Fig. 25 Hub Bearing Bolts
AXLE SHAFT
AXLE
KNUCKLE
Fig. 26 Hub Bearing and Axle Assembly
AXLE
KNUCKLE
HUB BEARING
Fig. 27 Steering Knuckle Removal/Installation
AXLE YOKE UPPER BALL STUD LOWER BALL STUD STEERING KNUCKLE
Fig. 28 Upper Ball Stud Remove/Install
REMOVAL
INSTALLATION
Fig. 29 Lower Ball Stud Remove/Install
SPECIAL TOOL 628912
SPECIAL TOOL 62894
KNUCKLE INSTALLATION
(1) Posi ti on the steeri ng knuckl e on the bal l studs.
(2) I nstal l and ti ghten the bottom retai ni ng nut to
109 Nm (80 ft. l bs.) torque. I nstal l new cotter pi n.
(3) I nstal l and ti ghten the top retai ni ng nut to 101
Nm (75 ft. l bs.) torque. I nstal l new cotter pi n.
(4) I nstal l the hub beari ng and axl e shaft.
(5) Connect the ti e-rod or drag l i nk end to the
steeri ng knuckl e arm. Refer to Group 2, Suspensi on,
AXLE BUSHING REPLACEMENT
Refer to Group 2, Suspensi on, for the proper axl e
bushi ng procedures.
DIFFERENTIAL
REMOVAL
al l ow fl ui d to drai n.
(4) Remove hub beari ngs and axl e shafts.
(5) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 30).
(6) Loosen the di fferenti al beari ng cap bol ts.
(7) Posi ti on Spreader W129B, uti l i zi ng some
i tems from Adapter Ki t 6987, wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 31). I nstal l the
hol ddown cl amps and ti ghten the tool turnbuckl e fi n-
gerti ght.
(8) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to gui de pi n. Load the l ever adapter agai nst the
opposi te si de of the housi ng (Fi g. 32) and zero the
i ndi cator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(9) Spread the housi ng enough to remove the di f-
ferenti al case from the housi ng. Measure the di s-
tance wi th the di al i ndi cator (Fi g. 33).
(10) Remove the di al i ndi cator.
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
(12) Remove the di fferenti al from the housi ng.
Ensure that the di fferenti al beari ng cups remai n i n
posi ti on on the di fferenti al beari ngs (Fi g. 34).
Fig. 30 Bearing Cap Identification
INSTALLATION REFER- ENCE LETTERS INSTALLATION REFER- ENCE LETTERS
Fig. 31 Install Axle Housing Spreader
AXLE HOUSING
DOWEL
SAFETY HOLD DOWN
Fig. 32 Install Dial Indicator
SPECIAL TOOL C-3339
DIAL INDICATOR
(13) Mark or tag the di fferenti al beari ng cups to
i ndi cate whi ch si de of the di fferenti al they were
removed from.
(14) Remove spreader from housi ng.
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are bei ng i nstal l ed, di fferenti al si de beari ng
shi m requi rements may change. Refer to the Di ffer-
enti al Beari ng Prel oad and Gear Backl ash proce-
dures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) Posi ti on Spreader W-129-B, uti l i zi ng some
i tems from Adapter Ki t 6987, wi th the tool dowel
hol ddown cl amps and ti ghten the tool turnbuckl e fi n-
gerti ght.
to gui de pi n. Load the l ever adapter agai nst the
i ndi cator.
damaged.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 33).
(5) I nstal l di fferenti al case i n the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs. Tap the di fferenti al case
to ensure the beari ngs cups are ful l y seated i n the
housi ng.
(6) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 36).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 61 Nm (45 ft.
l bs.) torque.
(10) I nstal l the hub beari ngs and axl e shafts.
DIFFERENTIAL SIDE BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
Fig. 33 Spread Axle Housing
SPECIAL TOOL C-3339
SPECIAL TOOL W-129B
Fig. 34 Differential Case Removal
AXLE HOUSING
DIFFERENTIAL CASE
BEARING CUPS
AXLE HOUSING
DOWEL
SAFETY HOLD DOWN
(2) Remove the beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, C-293-39 Bl ocks, and
Pl ug SP-3289 (Fi g. 37).
INSTALLATION
I f repl acement di fferenti al si de beari ngs or di ffer-
enti al case are bei ng i nstal l ed, di fferenti al si de bear-
i ng shi m requi rements may change. Refer to the
Di fferenti al Beari ng Prel oad and Gear Backl ash pro-
cedures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) Usi ng I nstal l er C-3716-A and Handl e C-4171,
i nstal l di fferenti al si de beari ngs (Fi g. 38).
(2) I nstal l di fferenti al i n axl e housi ng.
AXLE SHAFT OIL SEAL
REMOVAL
(2) Remove di fferenti al assembl y.
(3) Remove the i nner axl e shaft seal s wi th a pry
bay.
INSTALLATION
(1) Remove any seal er remai ni ng from ori gi nal
seal s.
(2) Remove seal er from axl e tube to housi ng junc-
ti on, i f necessary.
(3) I nstal l oi l seal s wi th Di scs 8110 and Turn-
buckl e 6797 (Fi g. 39). Ti ghten tool unti l di sc bottoms
i n housi ng.
(4) I nstal l di fferenti al assembl y.
PINION GEAR
NOTE: The ring and pinion gears are serviced as a
matched set. Do not replace the pinion gear without
replacing the ring gear.
Fig. 36 Differential Bearing Cap ReferenceLetters
Fig. 37 Differential Bearing Removal
SPECIAL TOOL C29339
BEARING
Fig. 38 Differential Side Bearing Installation
SPECIAL TOOL C-3716A SPECIAL TOOL C-4171
REMOVAL
i ng.
(2) Mark pi ni on yoke, or fl ange, and propel l er
shaft for i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from pi ni on yoke, or
fl ange. Usi ng sui tabl e wi re, ti e propel l er shaft to
underbody.
(4) Usi ng Hol der 6958 to hol d yoke, or fl ange, and
a short l ength of 1 i n. pi pe, remove the pi ni on nut
and washer (Fi g. 40).
(5) Usi ng Remover C452 and Hol der C-3281,
remove the pi ni on yoke, or fl ange, from pi ni on shaft
(Fi g. 41).
(6) Remove the pi ni on gear and col l apsi bl e spacer
from housi ng (Fi g. 42). Catch the pi ni on wi th your
hand to prevent i t from fal l i ng and bei ng damaged.
(7) Remove the front pi ni on beari ng cup, beari ng,
oi l sl i nger, i f equi pped, and pi ni on seal wi th Remover
C-4345 and Handl e C4171 (Fi g. 43).
(8) Remove the rear pi ni on beari ng cup from axl e
housi ng (Fi g. 44). Use Remover D-149 and Handl e
C4171.
(9) Remove the depth shi ms from rear pi ni on bear-
i ng cup bore i n axl e housi ng. Record the thi ckness of
the depth shi ms.
NOTE: The pinion depth shims can be very thin.
Verify that all shims have been removed before pro-
ceeding.
(10) Remove the col l apsi bl e prel oad spacer from
pi ni on gear (Fi g. 45).
Fig. 39 Axle Seal Installation
TURNBUCKLE 6797
DISCS 8110
Fig. 40 Pinion Yoke HolderTypical
1 in. PIPE
PINION YOKE
SPECIAL TOOL 6958
RAWHIDE HAM- MER
(11) Remove the rear pi ni on beari ng from the pi n-
i on wi th Pul l er/Press C293-PA and Adapters
C29339 (Fi g. 46).
Place 4 adapter blocks so they do not damage
the bearing cage.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing cup and axle housing to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin-
ion depth shim should not require replacement.
Refer to Pinion Gear Depth to select the proper
thickness shim before installing pinion gear.
(1) Pl ace proper thi ckness depth shi m i n rear pi n-
i on beari ng cup bore i n the axl e housi ng.
(2) Appl y Mopar Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of rear pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-146 and
Fig. 43 Front Bearing Cup Removal
REMOVER HANDLE
Fig. 44 Rear Bearing Cup Removal
DRIVER HANDLE
Fig. 45 Collapsible Spacer
Fig. 46 Inner Bearing Removal
SPECIAL TOOL C-293PA VISE ADAPTERS DRIVE PINION GEAR SHAFT
Dri ver Handl e C4171 (Fi g. 47). Veri fy cup i s cor-
rectl y seated.
l ubri cant to outsi de surface of front pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-130 and
Handl e C4171 (Fi g. 48).
(4) I nstal l front pi ni on beari ng, and oi l sl i nger, i f
equi pped.
and Handl e C4171 (Fi g. 49).
(6) I nstal l the rear pi ni on beari ng and oi l sl i nger,
i f equi pped, on the pi ni on gear wi th I nstal l er W-262
and a shop press (Fi g. 50).
i on shaft and i nstal l pi ni on gear i n housi ng (Fi g. 51).
(8) I nstal l yoke, or fl ange, wi th I nstal l er W-162-B,
Cup 8109, and Hol der 6958 (Fi g. 52).
i s 352 Nm (260 ft. l bs.).
be repeated.
Fig. 47 Rear Pinion Bearing Cup Installation
INSTALLER HANDLE
Fig. 48 Pinion Outer Bearing Cup Installation
INSTALLER HANDLE
SPECIAL TOOL C-4171
Fig. 50 Rear Pinion Bearing Installation
INSTALLA- TION TOOL OIL SLINGER DRIVE PINION GEAR DRIVE PINION GEAR SHAFT REAR BEARING
(260 ft. lbs.) of torque to crush, the collapsible
spacer is defective.
(10) Usi ng Hol der 6958, a short l ength of 1 i n.
pi pe, and torque wrench (set at 352 Nm (260 ft.
l bs.)), crush col l apsi bl e spacer unti l beari ng end pl ay
(11) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l b.)
(12) Check beari ng rotati ng torque wi th an i nch
pound torque wrench (Fi g. 54). The torque necessary
to rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs 1 to 3 Nm (10 to 20 i n.
l bs.).
(13) I nstal l di fferenti al assembl y.
RING GEAR
The ri ng and pi ni on gears are servi ce i n a matched
set. Do not repl ace the ri ng gear wi thout repl aci ng
the pi ni on gear.
PINION YOKE
AXLE HOUSING
Fig. 54 Check Pinion Gear Rotation Torque
in. lbs. TORQUE WRENCH
PINION YOKE
REMOVAL
(1) Remove di fferenti al from axl e housi ng.
(2) Pl ace di fferenti al case i n a sui tabl e vi se wi th
soft metal jaw protectors. (Fi g. 55)
(3) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(4) Usi ng a soft hammer, dri ve ri ng gear from di f-
ferenti al case (Fi g. 55).
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(1) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(2) I nvert the di fferenti al case i n the vi se.
(3) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 95122 Nm (7090 ft. l bs.) torque (Fi g.
56).
(4) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern.
DISASSEMBLY
(1) Remove the ri ng gear.
(2) Usi ng a sui tabl e rol l pi n punch, dri ve out the
rol l pi n hol di ng pi ni on gear mate shaft i n the di ffer-
enti al case (Fi g. 57).
(3) Remove the pi ni on gear mate shaft from the
di fferenti al case and the pi ni on mate gears.
(4) Rotate di fferenti al si de gears and remove the
pi ni on mate gears and thrust washers (Fi g. 58).
(5) Remove the di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l the di fferenti al si de gears and thrust
washers.
(2) I nstal l the pi ni on mate gears and thrust wash-
ers.
(3) I nstal l the pi ni on gear mate shaft. Al i gn the
rol l pi n hol es i n shaft and the di fferenti al case.
Fig. 55 Ring Gear Removal
CASE RING GEAR RAWHIDE HAM- MER
Fig. 56 Ring Gear Bolt Installation
TORQUE WRENCH RING GEAR BOLT RING GEAR CASE
Fig. 57 Mate Shaft Roll Pin Removal
DRIFT LOCKPIN MATE SHAFT
(4) I nstal l the rol l pi n to hol d the pi ni on mate
shaft i n the di fferenti al case (Fi g. 59).
(5) I nstal l the ri ng gear.
(6) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
FINAL ASSEMBLY
(1) Scrape the resi dual seal ant from the housi ng
and cover mati ng surfaces. Cl ean the mati ng surfaces
wi th mi neral spi ri ts. Appl y a bead of Mopar Si l i cone
Rubber Seal ant, or equi val ent, on the housi ng cover
(Fi g. 60).
(2) I nstal l the cover on the di fferenti al wi th the
attachi ng bol ts. I nstal l the i denti fi cati on tag. Ti ghten
the cover bol ts to 41 Nm (30 ft. l bs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(3) Refi l l the di fferenti al housi ng wi th gear l ubri -
cant. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the gear l ubri cant requi rements.
(4) I nstal l the fi l l hol e pl ug.
CARDAN U-JOINT
Cl ean al l the Ujoi nt yoke bores wi th cl eani ng sol -
vent and a wi re brush. Ensure that al l the rust and
forei gn matter are removed from the bores.
I nspect the yokes for di storti on, cracks and worn
beari ng cap bores.
Repl ace the compl ete Ujoi nt i f any of the compo-
nents are defecti ve.
AXLE COMPONENTS
Wash di fferenti al components wi th cl eani ng sol vent
and dry wi th compressed ai r. Do not steam clean
the differential components.
Fig. 58 Pinion Mate Gear Removal
THRUST WASHER SIDE GEAR PINION MATE GEAR
Fig. 59 Mate Shaft Roll Pin Installation
PUNCH PINION MATE SHAFT MATE SHAFT LOCKPIN
Wash beari ngs wi th sol vent and towel dry, or dry
wi th compressed ai r. DO NOT spi n beari ngs wi th
compressed ai r. Cup and bearing must be
replaced as matched sets only.
Cl ean axl e shaft tubes and oi l channel s i n housi ng.
I nspect for;
Smooth appearance wi th no broken/dented sur-
faces on the beari ng rol l ers or the rol l er contact sur-
faces.
Beari ng cups must not be di storted or cracked.
Machi ned surfaces shoul d be smooth and wi th-
out any rai sed edges.
Rai sed metal on shoul ders of cup bores shoul d
be removed wi th a hand stone.
Wear and damage to pi ni on gear mate shaft,
pi ni on gears, si de gears and thrust washers. Repl ace
as a matched set onl y.
Ri ng and pi ni on gear for worn and chi pped
teeth.
Ri ng gear for damaged bol t threads. Repl aced as
a matched set onl y.
Pi ni on yoke for cracks, worn spl i nes, pi tted
areas, and a rough/corroded seal contact surface.
Repai r or repl ace as necessary.
Prel oad shi ms for damage and di storti on. I nstal l
new shi ms, i f necessary.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
61). A pl us (+) number, mi nus () number or zero (0)
i s etched i nto the face of the pi ni on gear. Thi s num-
ber i s the amount (i n thousandths of an i nch) the
depth vari es from the standard depth setti ng of a
pi ni on etched wi th a (0). The standard setti ng from
the center l i ne of the ri ng gear to the back face of the
pi ni on i s 92.08 mm (3.625 i n.). The standard depth
provi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s paragraph i n
thi s secti on for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
behi nd the rear pi ni on beari ng cup (Fi g. 62).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (1, 2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
PINION DEPTH MEASUREMENT AND
ADJ USTMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the axl e housi ng
Fig. 61 Pinion Gear ID Numbers
PRODUCTION NUM- BERS DRIVE PINION GEAR DEPTH VARIANCE GEAR MATCHING NUMBER (SAME AS RING GEAR NUM- BER)
Fig. 62 Shim Locations
DRIVE PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM
CLEANING AND INSPECTION (Continued)
wi thout any shi ms pl aced behi nd the rear pi ni on
beari ng cup. Take measurements wi th Pi ni on Gauge
Set 6774 and Di al I ndi cator C-3339 (Fi g. 63).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6733, and rear pi ni on beari ng onto Screw 6741
(Fi g. 63).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto axl e housi ng through
pi ni on beari ng cups (Fi g. 64).
(3) I nstal l front pi ni on beari ng cone and Cone-nut
6740 hand ti ght (Fi g. 63).
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n axl e housi ng si de beari ng cradl es (Fi g. 65).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
PINION GEAR DEPTH VARIANCE
Original Pinion Gear Depth Variance Replacement Pinion Bear Depth Variance
Fig. 63 Pinion Gear Depth Gauge ToolsTypical
DIAL INDICATOR ARBOR PINION HEIGHT BLOCK CONE SCREW PINION BLOCK SCOOTER BLOCK ARBOR DISC
Fig. 64 Pinion Height BlockTypical
PINION BLOCK PINION HEIGHT BLOCK
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock (Fi g. 63). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator face to the poi nter. Ti ghten
di al i ndi cator face l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar wi th
the scooter bl ock agai nst the pi ni on hei ght bl ock (Fi g.
66). When the di al probe contacts the arbor bar, the di al
poi nter wi l l turn cl ockwi se. Bri ng di al poi nter back to
zero agai nst the arbor bar, do not turn di al face. Con-
ti nue movi ng the di al probe to the crest of the arbor bar
and record the hi ghest readi ng. I f the di al i ndi cator can
not achi eve the zero readi ng, the rear beari ng cup or
the pi ni on depth gauge set i s not i nstal l ed correctl y.
(9) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched i n the face of the pi ni on gear (Fi g. 61). For
exampl e, i f the depth vari ance i s 2, add +0.002 i n.
to the di al i ndi cator readi ng.
NOTE: If an oil slinger is used behind the inner pin-
ion bearing cone, deduct the thickness of the
slinger from the dial indicator reading and use that
total for shim selection.
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
INTRODUCTION
Di fferenti al si de beari ng prel oad and gear backl ash i s
achi eved by sel ecti ve shi ms posi ti oned behi nd the di ffer-
enti al si de beari ng cones. The proper shi m thi ckness
can be determi ned usi ng sl i p-fi t dummy beari ngs D-348
i n pl ace of the di fferenti al si de beari ngs and a di al i ndi -
cator C-3339. Before proceedi ng wi th the di fferenti al
beari ng prel oad and gear backl ash measurements, mea-
sure the pi ni on gear depth and prepare the pi ni on gear
for i nstal l ati on. Establ i shi ng proper pi ni on gear depth i s
essenti al to establ i shi ng gear backl ash and tooth con-
tact patterns. After the overal l shi m thi ckness to take
up di fferenti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s mea-
sured. The overal l shi m thi ckness i s the total of the di al
i ndi cator readi ng and the prel oad speci fi cati on added
together. The gear backl ash measurement determi nes
the thi ckness of the shi m used on the ri ng gear si de of
the di fferenti al case. Subtract the gear backl ash shi m
thi ckness from the total overal l shi m thi ckness and
sel ect that amount for the pi ni on gear si de of the di ffer-
enti al (Fi g. 67). Di fferenti al shi m measurements are
performed wi th axl e spreader W-129-B removed.
Fig. 65 Gauge Tools In HousingTypical
ARBOR DISC PINION BLOCK ARBOR PINION HEIGHT BLOCK
Fig. 66 Pinion Gear Depth MeasurementTypical
ARBOR SCOOTER BLOCK DIAL INDICATOR
Fig. 67 Axle Adjustment Shim Locations
DRIVE PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(4) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(5) I nstal l di fferenti al case i n axl e housi ng.
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts (Fi g. 68).
(7) Usi ng a dead-bl ow type mal l et, seat the di ffer-
enti al dummy beari ngs to each si de of the axl e hous-
i ng (Fi g. 69) and (Fi g. 70).
(8) Thread gui de stud C-3288-B i nto rear cover
bol t hol e bel ow ri ng gear (Fi g. 71).
(9) Attach a di al i ndi cator C-3339 to gui de stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
between the ri ng gear bol t heads (Fi g. 71).
(10) Push and hol d di fferenti al case to pi ni on gear
si de of axl e housi ng (Fi g. 72).
(11) Zero di al i ndi cator face to poi nter (Fi g. 72).
(12) Push and hol d di fferenti al case to ri ng gear
si de of the axl e housi ng (Fi g. 73).
(13) Record di al i ndi cator readi ng (Fi g. 73).
(14) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
Fig. 68 Tighten Bolts Holding Bearing Caps
BEARING CAP
AXLE HOUSING
DIFFERENTIAL CASE
Fig. 69 Seat Pinion Gear Side DifferentialDummy
Side Bearing
MALLET
AXLE HOUSING
DIFFERENTIAL CASE
Fig. 70 Seat Ring Gear Side DifferentialDummy Side
Bearing
AXLE HOUSING
MALLET
DIFFERENTIAL CASE
Fig. 71 Differential Side play Measurement
DIFFERENTIAL CASE
AXLE HOUSING
SPECIAL TOOL C-3288B
shi ms to compress, or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(15) Rotate di al i ndi cator out of the way on the
gui de stud.
(16) Remove di fferenti al case and dummy beari ngs
from axl e housi ng.
(17) I nstal l the pi ni on gear i n axl e housi ng. I nstal l
the pi ni on yoke, or fl ange, and establ i sh the correct
pi ni on rotati ng torque.
(18) I nstal l di fferenti al case and dummy beari ngs
D-348 i n axl e housi ng (wi thout shi ms), i nstal l bear-
i ng caps and ti ghten bol ts snug.
(19) Seat ri ng gear si de dummy beari ng (Fi g. 70).
(20) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads. (Fi g. 71).
(21) Push and hol d di fferenti al case toward pi ni on
gear (Fi g. 74).
(22) Zero di al i ndi cator face to poi nter (Fi g. 74).
si de of the axl e housi ng (Fi g. 75).
(24) Record di al i ndi cator readi ng (Fi g. 75).
(25) Subtract 0.002 i n. (0.05 mm) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(26) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(27) Rotate di al i ndi cator out of the way on gui de
stud.
(29) I nstal l si de beari ng shi ms on di fferenti al case
hubs.
(30) I nstal l si de beari ngs and cups on di fferenti al
case.
(31) I nstal l spreader W-129-B, uti l i zi ng some i tems
from Adapter Set 6987, on axl e housi ng and spread
axl e openi ng enough to recei ve di fferenti al case.
(33) Remove spreader from axl e housi ng.
Fig. 72 Hold Differential Case and Zero DialIndicator
FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
Fig. 73 Hold Differential Case and Read
DialIndicator
READ DIAL INDICATOR
FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
Fig. 74 Hold Differential Case and Zero DialIndicator
ZERO DIAL INDICATOR FACE
FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
Fig. 75 Hold Differential Case and Read
DialIndicator
READ DIAL INDICATOR
FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
(34) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(35) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 76).
(36) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(37) Zero di al i ndi cator face to poi nter.
(38) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the axl e housi ng to the other
(Fi g. 77).
(39) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at several
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN ANALYSIS
The ri ng and pi ni on gear teeth contact patterns
wi l l show i f the pi ni on gear depth i s correct i n the
axl e housi ng. I t wi l l al so show i f the ri ng gear back-
l ash has been adjusted correctl y. The backl ash can be
adjusted wi thi n speci fi cati ons to achi eve desi red
tooth contact patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de, or
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on gear. Thi s wi l l provi de a more di sti nct contact
pattern.
(3) Usi ng a boxed end wrench on a ri ng gear bol t,
Rotate the di fferenti al case one compl ete revol uti on
i n both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on gear teeth wi l l
squeegee the compound to the areas wi th the l east
amount of contact. Note and compare patterns on the
ri ng gear teeth to Gear Tooth Contact Patterns chart
(Fi g. 78) and adjust pi ni on depth and gear backl ash
as necessary.
SPECIFICATIONS
181 FBI AXLE
Axl e Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Hypoi d
Lubri cant . . . . . . . . SAE Thermal l y Stabl e 80W90
Lube Capaci ty . . . . . . . . . . . . . . . . . . 1.2 L (2.5 pts.)
Axl e Rati o . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.10
Di fferenti al Si de Gear Cl earance . . . . 0.120.20 mm
(0.0050.008 i n.)
Ri ng Gear Di ameter . . . . . . . . . 18.09 cm (7.125 i n.)
Backl ash . . . . . . . . . . . 00.15 mm (0.0050.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . . 92.1 mm (3.625 i n.)
Pi ni on Beari ng Rotati ng Torque . . . . . . . . . . . . . . . .
Ori gi nal Beari ngs . . . . . . . . 12 Nm (1020 i n. l bs.)
New Beari ngs . . . . . . . . . 1.54 Nm (1535 i n. l bs.)
Fig. 76 Ring Gear Backlash Measurement
DIAL INDI- CATOR
Fig. 77 Backlash Shim Adjustment
FOR MORE BACKLASH INCREASE SHIM THIS SIDE FOR MORE BACKLASH
DECREASE SHIM THIS
SIDE FOR LESS BACK-
LASH
FOR LESS BACKLASH
INCREASE SHIM THIS DIE
FOR LESS BACKLASH
DECREASE SHIM THIS
SIDE FOR MORE BACK-
LASH
Fig. 78 Gear Tooth Contact Patterns
DRIVE SIDE OF RING GEAR TEETH HEEL TOE COAST SIDE OF RING GEAR TEETH TOE HEEL DESIRABLE CONTACT PATTERN. PATTERN SHOULD BE CENTERED ON THE DRIVE SIDE OF TOOTH. PATTERN SHOULD BE CENTERED ON THE COAST SIDE OF TOOTH, BUT MAY BE SLIGHTLY TOWARD THE TOE. THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH. RING GEAR BACKLASH CORRECT. THINNER PINION GEAR DEPTH SHIM REQUIRED. RING GEAR BACKLASH CORRECT. THICKER PINION GEAR DEPTH SHIM REQUIRED. PINION GEAR DEPTH SHIM CORRECT. DECREASE RING GEAR BACKLASH. PINION GEAR DEPTH SHIM CORRECT. INCREASE RING GEAR BACKLASH.
SPECIFICATIONS (Continued)
181 FBI AXLE
DESCRIPTION TORQUE
Fill Hole Plug . . . . . . . . . . . . . . 34 Nm (25 ft. l bs.)
Diff. Cover Bolt . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bearing Cap Bolt . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Ring Gear Bolt . . . . . . 95122 Nm (7090 ft. l bs.)
Axle Nut . . . . . . . . . . . . . . . . 237 Nm (175 ft. l bs.)
Hub Brg. Bolt . . . . . . . . . . . . . 102 Nm (75 ft. l bs.)
Lower Ball Stud . . . . . . . . . . . 108 Nm (80 ft. l bs.)
Upper Ball Stud . . . . . . . . . . . 101 Nm (75 ft. l bs.)
SPECIAL TOOLS
181 FBI AXLE
PullerC-293-PA
PlugSP-3289
AdapterC-293-39
PullerC-452
WrenchC-3281
Dial IndicatorC-3339
DriverC-3716-A
HandleC-4171
InstallerD-146
RemoverD-149
InstallerW-162-D
Cup8109
Remover/Installer6289
Installer6761
SPECIAL TOOLS (Continued)
Installer6752
Installer Discs8110
Turnbuckle6797
Tool Set, Pinion Depth6774
Gauge Block6733
Puller7794-A
InstallerC-4975-A
Spanner6958
InstallerC-3972-A
SpreaderW-129-B
Adapter Kit6987
Pilot StudC-3288-B
RemoverC-4345
InstallerD-130
InstallerW-262
194 RBI AXLE
INDEX
page page
GENERAL INFORMATION
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 50
TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . 51
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . 52
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . 53
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 52
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . 53
TRACLOK DIFFERENTIAL NOISE . . . . . . . . . 53
TRACLOK TEST . . . . . . . . . . . . . . . . . . . . . . . 56
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SERVICE PROCEDURES
AXLE SHAFT SEAL AND BEARING . . . . . . . . . 62
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . 65
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 63
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 70
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 66
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . 72
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . 75
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ADJUSTMENTS
GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 78
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 76
SPECIFICATIONS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 82
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 82
SPECIAL TOOLS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 82
GENERAL INFORMATION
194 RBI AXLE
The 194 Rear Beam-desi gn I ron (RBI ) axl e housi ng
has an i ron center casti ng (di fferenti al housi ng) wi th
axl e shaft tubes extendi ng from ei ther si de. The
tubes are pressed i nto and wel ded to the di fferenti al
housi ng to form a one-pi ece axl e housi ng.
The i ntegral type, hypoi d gear desi gn, housi ng has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear.
The axl e has a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
shafts, meani ng that l oads are supported by the axl e
shaft and beari ngs. The axl e shafts are retai ned by
Ccl i ps i n the di fferenti al si de gears.
The cover provi des a means for servi ci ng the di ffer-
enti al wi thout removi ng the axl e.
For vehi cl es equi pped wi th ABS brakes, the axl es
have a tone ri ng pressed onto the axl e shaft. Use
care when removi ng axl e shafts to ensure that the
tone wheel or the wheel speed sensor are not dam-
aged.
The 194 RBI axl e has the assembl y part number
the di fferenti al housi ng by a cover bol t. Bui l d date
i denti fi cati on codes are stamped on the cover si de of
an axl e shaft tube.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash i s adjusted by the use of sel ecti ve
spacer shi ms. Pi ni on beari ng prel oad i s set and
mai ntai ned by the use of a col l apsi bl e spacer (Fi g. 1).
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
gear l ubri cant.
l ubri cant.
Trac-l ok di fferenti al s requi re the addi ti on of 4 oz.
of fri cti on modi fi er to the axl e l ubri cant. The 194 RBI
axl e l ubri cant capaci ty i s 1.66L (3.50 pts.) total ,
i ncl udi ng the fri cti on modi fi er i f necessary.
rotates the case
the shafts
speed.
TRAC-LOK OPERATION
I n a conventi onal di fferenti al , i f one wheel spi ns,
the opposi te wheel wi l l generate onl y as much torque
as the spi nni ng wheel .
I n the Trac-l ok di fferenti al , part of the ri ng gear
torque i s transmi tted through cl utch packs whi ch
contai n mul ti pl e di scs. The cl utches wi l l have radi al
grooves on the pl ates, and concentri c grooves on the
di scs or bonded fi ber materi al that i s smooth i n
appearance.
I n operati on, the Trac-l ok cl utches are engaged by
two concurrent forces. The fi rst bei ng the prel oad
force exerted through Bel l evi l l e spri ng washers
wi thi n the cl utch packs. The second i s the separati ng
forces generated by the si de gears as torque i s
appl i ed through the ri ng gear (Fi g. 4).
PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE RING GEAR DIFFERENTIAL BEARING SHIM-RING GEAR SIDE COLLAPSIBLE SPACER
AXLE
SPEED
SPEED
The Trac-l ok desi gn provi des the di fferenti al acti on
needed for turni ng corners and for dri vi ng strai ght
ahead duri ng peri ods of unequal tracti on. When one
wheel l ooses tracti on, the cl utch packs transfer addi -
ti onal torque to the wheel havi ng the most tracti on.
Trac-l ok di fferenti al s resi st wheel spi n on bumpy
roads and provi de more pul l i ng power when one
wheel l ooses tracti on. Pul l i ng power i s provi ded con-
ti nuousl y unti l both wheel s l oose tracti on. I f both
wheel s sl i p due to unequal tracti on, Trac-l ok opera-
ti on i s normal . I n extreme cases of di fferences of
tracti on, the wheel wi th the l east tracti on may spi n.
GENERAL INFORMATION
by:
of:
of:
GEAR NOISE
aged gears.
Gear damage.
BEARING NOISE
sound.
source.
Fig. 4 Trac-lok Limited Slip DifferentialOperation
CASE RING GEAR DRIVE PINION PINION GEAR MATE SHAFT CLUTCH PACK SIDE GEAR CLUTCH PACK
LOW SPEED KNOCK
knock.
VIBRATION
caused by a:
Worn Ujoi nt(s).
DRIVELINE SNAP
Worn Ujoi nts
Excessi ve ri ng gear backl ash
TRACLOK DIFFERENTIAL NOISE
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok uni t for
repai r, drai n, fl ush and refi l l the axl e wi th the spec-
i fi ed l ubri cant. Refer to Lubri cant change i n thi s
Group.
A contai ner of Mopar Trac-l ok Lubri cant (fri cti on
modi fi er) shoul d be added after repai r servi ce or dur-
i ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred
replaced.
AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1. Inspect axle shaft tube alignment. Correct
as necessary.
Adjustment.
4. Excessive gear backlash between ring
gear and pinion gear.
4. Check adjustment of ring gear backlash
and pinion gear. Correct as necessary.
shaft bearings.
6. Loose drive pinion gearshaft yoke nut. 6. Tighten drive pinion gearshaft yoke nut
with specified torque.
2. Vehicle overloaded. 2. Replace broken axle shaft. Avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken axle shaft after inspecting
for other possible casues. Avoid erratic use
of clutch.
4. Grabbing clutch. 4. Replace broken axle shaft. Inspect clutch
and make necessary repairs or adjustments.
DIFFERENTIAL CASE
CRACKED
1. Improper adjustment of differential
bearings.
1. Replace cracked case; examine gears and
bearings for possible damage. Avoid
bearings for possible damage. Avoid erratic
use of clutch.
DIFFERENTIAL
GEARS SCORED
1. Insufficient lubrication. 1. Replace scored gears. Scoring marks on
the drive face of gear teeth or in the bore are
surfaces. Scored gears should be replaced.
Fill rear differential housing to required
capacity with proper lubricant. Refer to
Specifications.
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all gears
and bearings for possible damage. Clean and
refill differential housing to required capacity
with proper lubricant.
pinion bores and shaft for damage. Service
as necessary.
and allow lubricant to level at lower edge of
fill plug hole.
necessary.
seal.
shaft seal.
seal.
and reseal.
GEAR AND PINION)
damage.
operation.
pinion gear.
set.
pinion gear.
matched set.
bearings.
torque.
bolts.
TRACLOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRACLOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRACLOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE.
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 to
studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 5).
(6) I f rotati ng torque i s l ess than 22 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
SERVICE PROCEDURES
LUBRICANT CHANGE
l i ght engi ne oi l , or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(5) Remove the ori gi nal seal ant from the housi ng
and cover surfaces.
Ti ghten the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(8) For Tracl ok di fferenti al s, a quanti ty of
Mopar Tracl ok l ubri cant (fri cti on modi fi er), or
equi val ent, must be added after repai r servi ce or a
l ubri cant change. Refer to the Lubri cant Speci fi ca-
ti ons secti on of thi s group for the quanti ty necessary.
(9) Fi l l di fferenti al wi th Mopar Hypoi d Gear
Lubri cant, or equi val ent, to bottom of the fi l l pl ug
hol e. Refer to the Lubri cant Speci fi cati ons secti on of
(11) Tracl ok di fferenti al equi pped vehi cl es shoul d
be road tested by maki ng 10 to 12 sl ow fi gure-ei ght
turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
REAR AXLE
REMOVAL
Fig. 5 Trac-lok Test Typical
SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE TORQUE WRENCH
Fig. 6 Apply Sealant
SEALANT AXLE HOUSING COVER
axl e.
(6) Di sconnect parki ng brake cabl es from brackets
and l ever.
(7) Remove wheel speed sensors, i f necessary.
(8) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the cal i pers. Refer to Group 5, Brakes, for proper
procedures.
tube.
(10) Mark the propel l er shaft and yokes for i nstal -
l ati on al i gnment reference.
(12) Di sconnect stabi l i zer bar l i nks.
(13) Di sconnect shock absorbers from axl e.
(15) Di sconnect upper and l ower suspensi on arms
from the axl e brackets.
(16) Separate the axl e from the vehi cl e.
INSTALLATION
NOTE: The weight of the vehicle must be sup-
are not at their normal ride position, vehicle ride
height and handling could be affected.
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn coi l
spri ngs.
on the axl e brackets. I nstal l nuts and bol ts, do not
ti ghten bol ts at thi s ti me.
(3) I nstal l track bar and attachment bol ts, do not
(4) I nstal l shock absorbers and ti ghten nuts to 60
(5) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
(6) I nstal l the wheel speed sensors, i f necessary.
(7) Connect parki ng brake cabl e to brackets and
l ever.
(9) Connect the brake hose to the axl e juncti on
bl ock. Refer to Group 5, Brakes, for proper proce-
dures.
(10) I nstal l axl e vent hose.
(11) Al i gn propel l er shaft and pi ni on yoke refer-
ence marks. I nstal l U-joi nt straps and bol ts. Ti ghten
(12) I nstal l the wheel s and ti res.
Lubri cant Speci fi cati ons i n thi s secti on for l ubri cant
requi rements.
(14) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(15) Ti ghten l ower suspensi on arm bol ts to 177
(16) Ti ghten upper suspensi on arm bol ts to 75 Nm
(55 ft. l bs.) torque.
(17) Ti ghten track bar bol ts to 100 Nm (74 ft. l bs.)
torque.
PINION SHAFT SEAL
REMOVAL
(3) Remove the brake rotors and cal i pers. Refer to
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on al i gnment reference.
(5) Remove the propel l er shaft from the yoke.
l ati on reference.
hol d the pi ni on yoke, remove the pi ni on nut and
washer (Fi g. 7).
(9) Use Remover C452 and Wrench C3281 to
remove the pi ni on yoke (Fi g. 8).
remove the pi ni on gear seal (Fi g. 9).
Fig. 7 Pinion Yoke Holder
1 in. PIPE
PINION YOKE
SPECIAL TOOL 6958
INSTALLATION
(2) I nstal l yoke on the pi ni on gear wi th Screw
8112, Cup 8109, and Hol der 6958 (Fi g. 11).
torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.
(3) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
(4) Ti ghten the nut to 271 Nm (200 ft. l bs.).
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 12).
shaft nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l the
(7) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and yoke and i nstal l the propel l er
shaft.
(8) Add gear l ubri cant to the di fferenti al housi ng,
i f necessary. Refer to the Lubri cant Speci fi cati ons for
gear l ubri cant requi rements.
Fig. 9 Seal Removal
SPECIAL TOOL C-4171
PINION YOKE
AXLE HOUSING
COLLAPSIBLE SPACER
(3) Remove rear brake rotors and cal i pers. Refer to
l ati on reference.
washer (Fi g. 14).
i on shaft.
SPECIAL TOOL 6958
1 in. PIPE
1 in. PIPE
PINION YOKE
SPECIAL TOOL 6958
l ati on reference.
i ng.
(9) Usi ng Hol der 6958 to hol d yoke and a short
l ength of 1 i n. pi pe, remove the pi ni on yoke nut and
washer (Fi g. 14).
(10) Usi ng Remover C452 and Wrench C3281,
remove the pi ni on yoke from pi ni on shaft (Fi g. 15).
INSTALLATION
i n housi ng.
(5) I nstal l yoke wi th Screw 8112, Cup 8109, and
Hol der 6958 (Fi g. 20).
sary.
are set.
pi ni on gear. Ti ghten the pi ni on nut unti l there i s zero
beari ng end-pl ay.
RAWHIDE HAM- MER
NOTE: If more than 474 Nm (350 ft. lbs.) of torque
is necessary to remove the bearing end play, the
collapsible spacer is defective and must be
replaced.
(12) I nstal l di fferenti al assembl y and axl e shafts,
i f necessary.
(13) Al i gn marks made previ ousl y on yoke and
propel l er shaft and i nstal l propel l er shaft.
(14) I nstal l rear brake rotors and cal i pers. Refer to
requi rements.
SPECIAL TOOL C-4171
PINION YOKE
AXLE HOUSING
SPECIAL TOOL 6958
1 in. PIPE
AXLE SHAFT
REMOVAL
(1) Rai se and support vehi cl e. Ensure that the
transmi ssi on i s i n neutral .
(3) Remove brake cal i per and rotor. Refer to Group
5, Brakes, for proper procedure.
(4) Cl ean al l forei gn materi al from housi ng cover
area.
(5) Loosen housi ng cover bol ts. Drai n l ubri cant
from the housi ng and axl e shaft tubes. Remove hous-
i ng cover.
(6) Rotate di fferenti al case so that pi ni on mate
gear shaft l ock screw i s accessi bl e. Remove l ock
screw and pi ni on mate gear shaft from di fferenti al
case (Fi g. 23).
(7) Push axl e shaft i nward and remove axl e shaft
Ccl i p l ock from the axl e shaft (Fi g. 24).
(8) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal , whi ch wi l l remai n i n
axl e shaft tube. Al so, exerci se care not to damage the
wheel speed sensor on vehi cl es equi pped wi th ABS
brakes.
(9) I nspect axl e shaft seal for l eakage or damage.
(10) I nspect rol l er beari ng contact surface on axl e
shaft for si gns of bri nel l i ng, gal l i ng and pi tti ng. I f
any of these condi ti ons exi st, the axl e shaft and/or
beari ng and seal must be repl aced.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip. Also, exercise care not to
damage the wheel speed sensor on vehicles
equipped with ABS brakes
(2) I nsert Ccl i p l ock i n end of axl e shaft. Push
axl e shaft outward to seat Ccl i p l ock i n si de gear.
(3) I nsert pi ni on mate shaft i nto di fferenti al case
and through thrust washers and pi ni on gears.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 19 Nm (14 ft. l bs.)
torque.
(5) I nstal l cover and add fl ui d. Refer to Lubri cant
Change procedure i n thi s secti on for procedure and
l ubri cant requi rements.
(6) I nstal l brake cal i per and rotor. Refer to Group
5, Brakes, for proper procedures.
(7) I nstal l wheel and ti re.
AXLE SHAFT SEAL AND BEARING
REMOVAL
(1) Remove the axl e shaft.
(2) Remove the axl e shaft seal from the end of the
axl e shaft tube wi th a smal l pry bar.
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove the axl e shaft beari ng from the axl e
tube wi th Beari ng Removal Tool Set 6310 usi ng
Adapter Foot 6310-5 (Fi g. 25).
(4) I nspect the axl e shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
Do not install the original axle shaft seal.
Always install a new seal.
(1) Wi pe the axl e shaft tube bore cl ean.
Fig. 23 Mate Shaft Lock Screw
LOCK SCREW PINION GEAR MATE SHAFT
Fig. 24 Axle Shaft CClip Lock
C-CLIPLOCK AXLESHAFT SIDE GEAR
(2) I nstal l axl e shaft beari ng wi th I nstal l er 6436
and Handl e C4171. Ensure that the part number on
the beari ng i s agai nst the i nstal l er.
(3) I nstal l the new axl e shaft seal wi th I nstal l er
6437 and Handl e C4171 (Fi g. 26).
(4) I nstal l the axl e shaft.
DIFFERENTIAL
REMOVAL
al l ow fl ui d to drai n.
(4) Remove axl e shafts.
(5) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 27).
(6) Loosen the di fferenti al beari ng cap bol ts.
i tems from Adapter set 6987, wi th the tool dowel pi ns
seated i n the l ocati ng hol es (Fi g. 28). I nstal l the hol d-
down cl amps and ti ghten the tool turnbuckl e fi nger-
ti ght.
(8) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
to pi l ot stud. Load the i ndi cator pl unger agai nst the
i ndi cator.
Fig. 25 Axle Shaft Bearing Removal
AXLE SHAFT TUBE NUT GUIDE PLATE GUIDE THREADED ROD ADAPTER FOOT
Fig. 26 Axle Shaft Seal Installation
SPECIAL TOOL 6437 SEAL AXLE SHAFT TUBE SPECIAL TOOL C-4171
AXLE HOUSING
DOWEL
SAFETY HOLD DOWN
the housing is overspread, it could be distorted or
damaged.
(9) Spread the housi ng enough to remove the di f-
ferenti al case from the housi ng. Measure the di s-
tance wi th the di al i ndi cator (Fi g. 30).
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
(12) Remove the di fferenti al from the housi ng.
Ensure that the di fferenti al beari ng cups remai n i n
posi ti on on the di fferenti al beari ngs (Fi g. 31).
(13) Mark or tag the di fferenti al beari ng cups to
i ndi cate whi ch si de of the di fferenti al they were
removed from.
(14) Retri eve di fferenti al case prel oad shi ms from
axl e housi ng. Mark or tag the di fferenti al case pre-
l oad shi ms to i ndi cate whi ch si de of the di fferenti al
they were removed from.
(15) Remove spreader from housi ng.
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are bei ng i nstal l ed, di fferenti al si de beari ng
shi m requi rements may change. Refer to the Di ffer-
enti al Beari ng Prel oad and Gear Backl ash proce-
dures i n thi s secti on to determi ne the proper shi m
sel ecti on.
i tems from Adapter set 6987, wi th the tool dowel pi ns
seated i n the l ocati ng hol es (Fi g. 32). I nstal l the hol d-
down cl amps and ti ghten the tool turnbuckl e fi nger-
ti ght.
(2) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
to pi l ot stud. Load the i ndi cator pl unger agai nst the
i ndi cator.
the housing is overspread, it could be distorted or
damaged.
(5) I nstal l di fferenti al case i n the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs and that the prel oad
shi ms remai n between the face of the beari ng cup
Fig. 29 Install Dial Indicator
SPECIAL TOOL C-3339
DIAL INDICATOR
Fig. 30 Spread Axle Housing
SPECIAL TOOL C-3339
SPECIAL TOOL W-129B
Fig. 31 Differential Case Removal
AXLE HOUSING
DIFFERENTIAL CASE
BEARING CUPS
and the housi ng. Tap the di fferenti al case to ensure
the beari ngs cups and shi ms are ful l y seated i n the
housi ng.
ti ons (Fi g. 33).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 77 Nm (57 ft.
l bs.) torque.
(10) I nstal l the axl e shafts.
REMOVAL
wi th Pul l er/Press C-293-PA, C-293-39 Bl ocks, and
Pl ug SP-3289 (Fi g. 34).
INSTALLATION
(1) Usi ng tool C-3716-A wi th handl e C-4171,
i nstal l di fferenti al si de beari ngs (Fi g. 35).
(2) I nstal l di fferenti al i n axl e housi ng.
RING GEAR
the pi ni on gear.
REMOVAL
case.
INSTALLATION
AXLE HOUSING
DOWEL
SAFETY HOLD DOWN
SPECIAL TOOL C-29339
BEARING
hol e al i gnment.
56).
PINION GEAR
The ri ng and pi ni on gears are servi ced i n a
matched set. Do not repl ace the pi ni on gear wi thout
repl aci ng the ri ng gear.
REMOVAL
(1) Remove di fferenti al from the axl e housi ng.
(2) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from pi ni on yoke.
Usi ng sui tabl e wi re, ti e propel l er shaft to underbody.
washer (Fi g. 38).
Fig. 35 Install DifferentialSide Bearings
HANDLE C-4171 DIFFERENTIAL BEARING TOOL C-3716A
1 in. PIPE PINION YOKE SPECIAL TOOL 6958 LOWER CONTROL ARM
(6) Remove the pi ni on gear from housi ng (Fi g. 40).
Catch the pi ni on wi th your hand to prevent i t from
fal l i ng and bei ng damaged.
(8) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(9) Remove the front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C4171 (Fi g. 42).
RAWHIDE HAM- MER
REMOVER HANDLE
(10) Remove the rear beari ng cup from housi ng
(Fi g. 43). Use Remover D-149 and Handl e C4171.
(11) Remove the col l apsi bl e prel oad spacer (Fi g.
44).
(12) Remove the rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-40 (Fi g.
45).
the bearing cage.
(13) Remove the depth shi ms from the pi ni on gear
shaft. Record the thi ckness of the depth shi ms.
INSTALLATION
l ubri cant to outsi de surface of beari ng cup.
(2) I nstal l the pi ni on rear beari ng cup wi th
I nstal l er D-146 and Dri ver Handl e C4171 (Fi g. 46).
Ensure cup i s correctl y seated.
l ubri cant to outsi de surface of beari ng cup.
DRIVER HANDLE
Fig. 45 Rear Bearing Removal
Fig. 46 Pinion Rear Bearing Cup Installation
INSTALLER HANDLE
(4) I nstal l the pi ni on front beari ng cup wi th
I nstal l er D130 and Handl e C4171 (Fi g. 47).
(5) I nstal l pi ni on front beari ng, and oi l sl i nger, i f
equi pped.
rear pinion bearing cone and pinion gear to achieve
ion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
bearing.
(7) Pl ace the proper thi ckness depth shi m on the
pi ni on gear.
(8) I nstal l the rear beari ng and sl i nger, i f
equi pped, on the pi ni on gear wi th I nstal l er W-262
(Fi g. 49).
i on shaft and i nstal l pi ni on gear i n housi ng (Fi g. 50).
(10) I nstal l pi ni on gear i n housi ng.
(11) I nstal l yoke wi th I nstal l er Screw 8112, Cup
8109, and hol der 6958 (Fi g. 51).
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
Fig. 47 Pinion Front Bearing Cup Installation
INSTALLER HANDLE
SPECIAL TOOL C-4171
Fig. 49 Shaft Rear Bearing Installation
PRESS INSTALLATION TOOL DRIVE PINION GEAR DRIVE PINION GEAR SHAFT REAR BEARING
(350 ft. lbs.) torque to crush, the collapsible spacer
is defective and must be replaced.
l bs.).
(17) I nstal l di fferenti al i n housi ng.
FINAL ASSEMBLY
(Fi g. 60).
PINION YOKE
AXLE HOUSING
SPECIAL TOOL 6958
1 in. PIPE
Fig. 53 Check Pinion Gear Rotating Torque
DISASSEMBLY
(1) Remove pi ni on gear mate shaft l ock screw (Fi g.
55).
(2) Remove pi ni on gear mate shaft.
(3) Rotate the di fferenti al si de gears and remove
the pi ni on mate gears and thrust washers (Fi g. 56).
washers.
ASSEMBLY
washers.
ers.
(3) I nstal l the pi ni on gear mate shaft.
(4) Al i gn the hol e i n the pi ni on gear mate shaft
wi th the hol e i n the di fferenti al case and i nstal l the
pi ni on gear mate shaft l ock screw.
Fig. 55 Pinion Gear Mate Shaft Lock Screw
TRAC-LOK DIFFERENTIAL
The Tracl ok di fferenti al components are i l l ustrated i n
(Fi g. 57). Refer to thi s i l l ustrati on duri ng repai r servi ce.
DISASSEMBLY
(1) Cl amp Si de Gear Hol di ng Tool 6965 i n a vi se.
(2) Posi ti on the di fferenti al case on Si de Gear
Hol di ng Tool 6965 (Fi g. 58).
(3) Remove ri ng gear, i f necessary. Ri ng gear
removal i s necessary onl y i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(4) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 59).
(5) Remove the pi ni on gear mate shaft. I f neces-
sary, use a dri ft and hammer (Fi g. 60).
(6) I nstal l and l ubri cate Step Pl ate C-6960-3 (Fi g.
61).
(7) Assembl e Threaded Adapter C-6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
Fig. 57 Traclok Differential Components
THRUST WASHER
PINION
SHAFT LOCK SCREW
Fig. 58 Differential Case Holding Tool
SPECIAL TOOL 6965
VISE
(8) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter C-6960-1 (Fi g. 62) to prevent
adapter from turni ng.
(9) Ti ghten forci ng screw tool 122 Nm (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 63).
(10) Usi ng an appropri ate si ze feel er gauge,
remove thrust washers from behi nd the pi ni on gears
(Fi g. 64).
(11) I nsert Turni ng Bar C-6960-2 i n case (Fi g. 65).
(12) Loosen the Forci ng Screw C-6960-4 i n smal l
i ncrements unti l the cl utch pack tensi on i s rel i eved
and the di fferenti al case can be turned usi ng Turni ng
Bar C-6960-2.
(13) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(14) Remove pi ni on gears from di fferenti al case.
(15) Remove Forci ng Screw C-6960-4, Step Pl ate
C-6960-3, and Threaded Adapter C-6960-1.
(16) Remove top si de gear, cl utch pack retai ner,
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 66).
(17) Remove di fferenti al case from Si de Gear Hol d-
i ng Tool 6965. Remove si de gear, cl utch pack retai ner,
removal .
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Fig. 60 Mate Shaft Removal
PINION MATE SHAFT
SIDE GEAR
DRIFT
Fig. 61 Step Plate Tool Installation
LOWER SIDE GEAR
DIFFERENTIAL CASE
Fig. 62 Threaded Adapter Installation
SOCKET
SLOT IN ADAPTER
SCREWDRIVER
Fig. 63 Tighten Belleville Spring CompressorTool
TORQUE WRENCH TOOL ASSEM- BLED DIFFERENTIAL CASE
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 67).
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 68). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
Hol di ng Tool 6965.
(5) I nstal l l ubri cated Step Pl ate C-6960-3 i n l ower
si de gear (Fi g. 69).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 69).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C-6960-1 i nto top si de gear.
(8) I nsert Forci ng Screw C-6960-4.
(9) Ti ghten forci ng screw tool to sl i ghtl y compress
cl utch di scs.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar C-6960-2 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
Fig. 64 Remove Pinion Gear Thrust Washer
THRUST WASHER
FEELER GAUGE
Fig. 65 Pinion Gear Removal
PINION GEARS TOOL
Fig. 66 Side Gear & ClutchDisc Removal
DIFFERENTIAL CASE
RETAINER
SIDE GEAR AND CLUTCH DISC PACK
Fig. 67 Clutch Disc Pack
CLUTCH PACK RETAINER SIDE GEAR RETAINER
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw C-6960-4, Step Pl ate
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l the pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
AXLE COMPONENTS
I nspect for;
faces.
teeth.
TRAC-LOK
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de and pi ni on gears. Repl ace any
gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
Fig. 68 Clutch Discs & Lower Side GearInstallation
DIFFERENTIAL CASE
LOWER SIDE GEAR AND CLUTCH DISC PACK
Fig. 69 Upper Side Gear & Clutch DiscPack
Installation
UPPER SIDE GEAR AND CLUTCH DISC PACK
DIFFERENTIAL CASE
PRESOAK PLATES AND DISC
Pl ates and di scs wi th fi ber coati ng (no grooves or
l i nes) must be presoaked i n Fri cti on Modi fi er before
assembl y. Soak pl ates and di scs for a mi ni mum of 20
mi nutes.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
provi des the best teeth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s Paragraph i n
under the i nner pi ni on beari ng cone (Fi g. 71).
ance charts.
mi nus amount needed.
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
ADJ USTMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 6735,
Arbor Di scs 6732, and Di al I ndi cator C-3339 (Fi g.
72).
(Fi g. 72).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght (Fi g. 72).
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons
i n thi s secti on.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
fl ush agai nst the surface of the pi ni on hei ght bl ock.
Hol d scooter bl ock i n pl ace and zero the di al i ndi ca-
PINION GEAR DEPTH SHIM
DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
tor face to the poi nter. Ti ghten di al i ndi cator face
l ock screw.
Observe how many revol uti ons countercl ockwi se the
di al poi nter travel s (approxi matel y 0.125 i n.) to the
out-stop of the di al i ndi cator.
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 75). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
etched i n the face of the pi ni on gear (Fi g. 70) usi ng
the opposi te si gn on the vari ance number. For exam-
pl e, i f the depth vari ance i s 2, add +0.002 i n. to the
di al i ndi cator readi ng.
(10) Remove the pi ni on depth gauge components
from the axl e housi ng
BACKLASH
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the axl e housi ng. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs D-348 i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on gear for i nstal l ati on. Estab-
l i shi ng proper pi ni on gear depth i s essenti al to estab-
l i shi ng gear backl ash and tooth contact patterns.
After the overal l shi m thi ckness to take up di fferen-
ti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of
the di al i ndi cator readi ng, starti ng poi nt shi m thi ck-
ness, and the prel oad speci fi cati on added together.
The gear backl ash measurement determi nes the
thi ckness of the shi m used on the ri ng gear si de of
sel ect that amount for the pi ni on gear si de of the di f-
ferenti al (Fi g. 76).
SHIM SELECTION
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear, i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
(3) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(5) I nsert Dummy Shi ms 8107 (0.118 i n. (3.0 mm))
starti ng poi nt shi ms between the dummy beari ng
and the axl e housi ng (Fi g. 77).
posi ti ons. I nstal l and ti ghten the bol ts.
(8) Attach di al i ndi cator C-3339 to gui de stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
on a ri ng gear bol t head (Fi g. 78).
(9) Push fi rml y and hol d di fferenti al case to pi ni on
gear si de of axl e housi ng.
(11) Push fi rml y and hol d di fferenti al case to ri ng
gear si de of the axl e housi ng.
(12) Record di al i ndi cator readi ng.
(13) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
stud.
(16) Remove di fferenti al case, dummy beari ngs,
and starti ng poi nt shi ms from axl e housi ng.
(17) I nstal l pi ni on gear i n axl e housi ng. I nstal l the
yoke and establ i sh the correct pi ni on rotati ng torque.
i n axl e housi ng (wi thout shi ms) and ti ghten retai ni ng
cap bol ts.
surface between the ri ng gear bol t heads (Fi g. 78).
gear.
si de of the axl e housi ng.
ri ng and pi ni on gears. Thi s total i s the thi ckness of
axl e housi ng.
stud.
(28) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(29) I nstal l spreader W-129-B, uti l i zi ng some com-
ponents of Adapter Set 6987, on axl e housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(30) Pl ace si de beari ng shi ms i n axl e housi ng
agai nst axl e tubes.
ness from one si de of the di fferenti al housi ng to the
other (Fi g. 80).
Fig. 77 Insert Starting Point Shims
After the proper backl ash i s achi eved, perform the
gear teeth.
pattern.
shop towel .
as necessary.
DIAL INDI- CATOR
DECREASE SHIM THIS
SIDE FOR LESS BACK-
LASH
FOR LESS BACKLASH
FOR LESS BACKLASH
DECREASE SHIM THIS
SIDE FOR MORE BACK-
LASH
SPECIFICATIONS
194 RBI AXLE
DESCRIPTION SPECIFICATION
Axl e Type . . . . . . . . . . . . . . . Semi Fl oati ng Hypoi d
Lubri cant . . . . . . . . SAE Thermal l y Stabl e 80W90
Lubri cant Trai l er Tow . . . . . . . . Syntheti c 75W140
Lube Capaci ty . . . . . . . . . . . . . . . . 1.66 L (3.50 pts.)
Axl e Rati os . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.10
Di fferenti al Beari ng Prel oad . . . . 0.1 mm (0.004 i n.)
Di fferenti al Si de Gear Cl earance . . . . . . 00.15 mm
(00.006 i n.)
Ri ng Gear Di ameter . . . . . . . . . . 19.2 cm (7.562 i n.)
Ri ng Gear Backl ash . . . 00.15 mm (0.0050.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . 92.08 mm (3.625 i n.)
Pi ni on Beari ng Prel oad-Ori gi nal
Beari ngs . . . . . . . . . . . . . 12 Nm (1020 i n. l bs.)
Pi ni on Beari ng Prel oad-New
Beari ngs . . . . . . . . . . . 1.54 Nm (1535 i n. l bs.)
194 RBI AXLE
DESCRIPTION TORQUE
Bolt, Diff. Cover . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bolot, Bearing Cap . . . . . . . . . 77 Nm (57 ft. l bs.)
Nut, Pinion . . . . . . 271474 Nm (200350 ft. l bs.)
Screw, Pinion Mate
Shaft Lock . . . . . . . . . . . . 16.25 Nm (12 ft. l bs.)
Bolt, Ring Gear . . . . . . 95122 Nm (7090 ft. l bs.)
Bolt, RWAL/ABS Sensor . . . . . . 8 Nm (70 i n. l bs.)
SPECIAL TOOLS
194 RBI AXLE
PullerC-293-PA
AdapterC-293-39
AdapterC-293-40
PlugSP-3289
PullerC-452
WrenchC-3281
InstallerC-3972-A
Spanner6958
Installer Screw8112
Cup8109
HandleC-4171
DriverC-3716-A
InstallerD-130
InstallerD-146
RemoverC-4345
RemoverD-149
InstallerW-262
Installer6436
Installer6437
Disc, Axle Arbor6732
Gauge Block6735
Tool Set, Pinion Depth6774
Trac-lok Tool Set6960
Holder6965
Puller7794-A
Starting Point Shim8107
SpreaderW-129-B
Adapter Kit6987
Guide PinC-3288-B
Bearing Remover Tool Set6310
Hub Puller6790
216 RBA AXLE
INDEX
page page
GENERAL INFORMATION
216 RBA AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 87
TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . 88
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . 89
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . 90
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 89
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . 90
TRACLOK DIFFERENTIAL NOISE . . . . . . . . . 90
TRACLOK TEST . . . . . . . . . . . . . . . . . . . . . . . 93
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
SERVICE PROCEDURES
AXLE SHAFT SEAL AND BEARING . . . . . . . . . 99
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 98
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . 101
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . 100
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 106
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . 103
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 101
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . 107
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . 107
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . 111
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
ADJUSTMENTS
GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . 113
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . 111
SPECIFICATIONS
216 RBA AXLE . . . . . . . . . . . . . . . . . . . . . . . . 118
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
SPECIAL TOOLS
216 RBA AXLE . . . . . . . . . . . . . . . . . . . . . . . . 118
GENERAL INFORMATION
216 RBA AXLE
The 216 Rear Beam-desi gn Al umi num (RBA) axl e
housi ng has an al umi num center casti ng (di fferenti al
housi ng) wi th axl e shaft tubes extendi ng from ei ther
si de. The tubes are pressed i nto the di fferenti al hous-
i ng to form a onepi ece axl e housi ng.
The i ntegral type housi ng, hypoi d gear desi gn has
the center-l i ne of the pi ni on set bel ow the center-l i ne
of the ri ng gear.
The axl e has a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
shafts, meani ng that vehi cl e l oad i s supported by the
axl e shaft and beari ngs. The axl e shafts are retai ned
by Ccl i ps i n the di fferenti al si de gears.
The cover provi des a means for servi ci ng the di ffer-
enti al wi thout removi ng the axl e.
For vehi cl es equi pped wi th ABS brakes, the axl es
have a tone ri ng pressed onto the axl e shaft. Use
care when removi ng axl e shafts to ensure that the
tone wheel or the wheel speed sensor are not dam-
aged.
The 216 RBA axl e has the assembl y part number
the di fferenti al housi ng by a cover bol t. Bui l d date
i denti fi cati on codes are stamped on the cover si de of
an axl e shaft tube.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash i s adjusted by the use of sel ecti ve
spacer shi ms. Pi ni on beari ng prel oad i s set and
mai ntai ned by the use of a col l apsi bl e spacer (Fi g. 1).
A mul ti purpose, hypoi d gear l ubri cant whi ch con-
gear l ubri cant.
l ubri cant.
Trac-l ok di fferenti al s requi re the addi ti on of 4 oz.
of fri cti on modi fi er to the axl e l ubri cant. The 216
RBA axl e l ubri cant capaci ty i s 2.25 L (4.75 pts.) total ,
i ncl udi ng the fri cti on modi fi er i f necessary.
rotates the case
the shafts
speed.
TRAC-LOK OPERATION
I n a conventi onal di fferenti al , i f one wheel spi ns,
the opposi te wheel wi l l generate onl y as much torque
as the spi nni ng wheel .
I n the Trac-l ok di fferenti al , part of the ri ng gear
torque i s transmi tted through cl utch packs whi ch
contai n mul ti pl e di scs. The cl utches wi l l have radi al
grooves on the pl ates, and concentri c grooves on the
di scs or bonded fi ber materi al that i s smooth i n
appearance.
I n operati on, the Trac-l ok cl utches are engaged by
two concurrent forces. The fi rst bei ng the prel oad
force exerted through Bel l evi l l e spri ng washers
wi thi n the cl utch packs. The second i s the separati ng
forces generated by the si de gears as torque i s
appl i ed through the ri ng gear (Fi g. 4).
AXLE
SPEED
SPEED
The Trac-l ok desi gn provi des the di fferenti al acti on
needed for turni ng corners and for dri vi ng strai ght
ahead duri ng peri ods of unequal tracti on. When one
wheel l ooses tracti on, the cl utch packs transfer addi -
ti onal torque to the wheel havi ng the most tracti on.
Trac-l ok di fferenti al s resi st wheel spi n on bumpy
roads and provi de more pul l i ng power when one
wheel l ooses tracti on. Pul l i ng power i s provi ded con-
ti nuousl y unti l both wheel s l oose tracti on. I f both
wheel s sl i p due to unequal tracti on, Trac-l ok opera-
ti on i s normal . I n extreme cases of di fferences of
tracti on, the wheel wi th the l east tracti on may spi n.
GENERAL INFORMATION
by:
of:
of:
GEAR NOISE
aged gears.
Gear damage.
BEARING NOISE
sound.
source.
Fig. 4 Trac-lok Limited Slip DifferentialOperation
CASE RING GEAR DRIVE PINION PINION GEAR MATE SHAFT CLUTCH PACK SIDE GEAR CLUTCH PACK
LOW SPEED KNOCK
knock.
VIBRATION
caused by a:
Worn Ujoi nt(s).
DRIVELINE SNAP
Worn Ujoi nts
Excessi ve ri ng gea r backl ash
TRACLOK DIFFERENTIAL NOISE
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok uni t for
repai r, drai n, fl ush and refi l l the axl e wi th the spec-
i fi ed l ubri cant. Refer to Lubri cant change i n thi s
Group.
A contai ner of Mopar Trac-l ok Lubri cant (fri cti on
modi fi er) shoul d be added after repai r servi ce or dur-
i ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
replaced.
AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1. Inspect axle shaft tube alignment. Correct
as necessary.
Adjustment.
4. Excessive gear backlash between ring
gear and pinion gear.
4. Check adjustment of ring gear backlash
and pinion gear. Correct as necessary.
shaft bearings.
6. Loose drive pinion gearshaft yoke nut. 6. Tighten drive pinion gearshaft yoke nut
with specified torque.
2. Vehicle overloaded. 2. Replace broken axle shaft. Avoid
3. Erratic clutch operation. 3. Replace broken axle shaft after inspecting
for other possible casues. Avoid erratic use
of clutch.
4. Grabbing clutch. 4. Replace broken axle shaft. Inspect clutch
and make necessary repairs or adjustments.
DIFFERENTIAL CASE
CRACKED
1. Improper adjustment of differential
bearings.
1. Replace cracked case; examine gears and
bearings for possible damage. Avoid
bearings for possible damage. Avoid erratic
use of clutch.
DIFFERENTIAL
GEARS SCORED
1. Insufficient lubrication. 1. Replace scored gears. Scoring marks on
the drive face of gear teeth or in the bore are
surfaces. Scored gears should be replaced.
Fill rear differential housing to required
capacity with proper lubricant. Refer to
Specifications.
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all gears
and bearings for possible damage. Clean and
refill differential housing to required capacity
with proper lubricant.
pinion bores and shaft for damage. Service
as necessary.
and allow lubricant to level at lower edge of
fill plug hole.
necessary.
seal.
shaft seal.
seal.
and reseal.
GEAR AND PINION)
damage.
operation.
pinion gear.
set.
pinion gear.
matched set.
bearings.
torque.
bolts.
TRACLOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRACLOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRACLOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE.
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 to
studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 5).
(6) I f rotati ng torque i s l ess than 22 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
SERVICE PROCEDURES
LUBRICANT CHANGE
l i ght engi ne oi l , or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(5) Remove the ori gi nal seal ant from the housi ng
and cover surfaces.
Ti ghten the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(8) For Tracl ok di fferenti al s, a quanti ty of
Mopar Tracl ok l ubri cant (fri cti on modi fi er), or
equi val ent, must be added after repai r servi ce or a
l ubri cant change. Refer to the Lubri cant Speci fi ca-
ti ons secti on of thi s group for the quanti ty necessary.
(9) Fi l l di fferenti al wi th Mopar Hypoi d Gear
Lubri cant, or equi val ent, to bottom of the fi l l pl ug
hol e. Refer to the Lubri cant Speci fi cati ons secti on of
(11) Tracl ok di fferenti al equi pped vehi cl es shoul d
be road tested by maki ng 10 to 12 sl ow fi gure-ei ght
turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
REAR AXLE
REMOVAL
Fig. 5 Trac-lok Test Typical
SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
TORQUE WRENCH
Fig. 6 Apply Sealant
SEALANT
AXLE HOUSING COVER
axl e.
(6) Di sconnect parki ng brake cabl es from brackets
and l ever.
(7) Remove wheel speed sensors, i f necessary.
(8) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the cal i pers. Refer to Group 5, Brakes, for proper
procedures.
tube.
(10) Mark the propel l er shaft and yokes for i nstal -
(12) Di sconnect stabi l i zer bar l i nks.
(13) Di sconnect shock absorbers from axl e.
(15) Di sconnect upper and l ower suspensi on arms
from the axl e brackets.
(16) Separate the axl e from the vehi cl e.
INSTALLATION
NOTE: The weight of the vehicle must be sup-
are not at their normal ride position, vehicle ride
height and handling could be affected.
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn coi l
spri ngs.
on the axl e brackets. I nstal l nuts and bol ts, do not
(3) I nstal l track bar and attachment bol ts, do not
(4) I nstal l shock absorbers and ti ghten nuts to 60
(5) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
(6) I nstal l the wheel speed sensors, i f necessary.
(7) Connect parki ng brake cabl e to brackets and
l ever.
(9) Connect the brake hose to the axl e juncti on
bl ock. Refer to Group 5, Brakes, for proper proce-
dures.
(10) I nstal l axl e vent hose.
(11) Al i gn propel l er shaft and pi ni on yoke refer-
ence marks. I nstal l U-joi nt straps and bol ts. Ti ghten
(12) I nstal l the wheel s and ti res.
Lubri cant Speci fi cati ons i n thi s secti on for l ubri cant
requi rements.
(14) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(15) Ti ghten l ower suspensi on arm bol ts to 177
(16) Ti ghten upper suspensi on arm bol ts to 75 Nm
(17) Ti ghten track bar bol ts to 100 Nm (74 ft. l bs.)
torque.
PINION SHAFT SEAL
REMOVAL
l ati on reference.
washer (Fi g. 7).
1 in. PIPE
PINION YOKE
SPECIAL TOOL 6958
INSTALLATION
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
C-3718 and Hol der 6958 (Fi g. 11).
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bear-
ings may result.
(3) I nstal l a new nut on the pi ni on gear. Tighten
the nut only enough to remove the shaft end
play.
wrench. Rotati ng resi stance torque shoul d be equal
to the readi ng recorded duri ng removal , pl us an addi -
ti onal 0.56 Nm (5 i n. l bs.) (Fi g. 12).
Fig. 9 Seal Removal
SPECIAL TOOL C-4171
SPECIAL TOOL C-3718
PINION YOKE
shaft nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l
(6) Al i gn the i nstal l ati on reference marks on pro-
pel l er shaft and yoke and i nstal l the propel l er shaft.
(7) Add gear l ubri cant to the di fferenti al housi ng,
i f necessary. Refer to the Lubri cant Speci fi cati ons for
gear l ubri cant requi rements.
(8) I nstal l brake rotors and cal i pers. Refer to
COLLAPSIBLE SPACER
l ati on reference.
washer (Fi g. 14).
i on shaft.
l ati on reference.
i ng.
SPECIAL TOOL 6958
1 in. PIPE
1 in. PIPE
PINION YOKE
SPECIAL TOOL 6958
washer (Fi g. 14).
INSTALLATION
i n housi ng.
(5) I nstal l yoke wi th I nstal l er C3718 and Hol der
6958 (Fi g. 20).
sary.
are set.
RAWHIDE HAM- MER
SPECIAL TOOL C-4171
i s 380 Nm (280 ft. l bs.).
be repeated.
NOTE: If the spacer requires more than 280 ft. lbs.
torque to crush, the collapsible spacer is defective.
(11) I nstal l di fferenti al assembl y and axl e shafts, i f
necessary.
(12) Al i gn marks made previ ousl y on yoke and
(13) I nstal l rear brake rotors and cal i pers. Refer to
Group 5 Brakes, for proper procedures.
requi rements.
AXLE SHAFT
REMOVAL
(1) Rai se and support vehi cl e. Ensure that the
transmi ssi on i s i n neutral .
(3) Remove brake cal i per and rotor. Refer to Group
5, Brakes, for proper procedure.
(4) Cl ean al l forei gn materi al from housi ng cover
area.
(5) Loosen housi ng cover bol ts. Drai n l ubri cant
from the housi ng and axl e shaft tubes. Remove hous-
i ng cover.
SPECIAL TOOL C-3718
PINION YOKE
SPECIAL TOOL 6958
1 in. PIPE
(6) Rotate di fferenti al case so that pi ni on mate
gear shaft l ock screw i s accessi bl e. Remove l ock
screw and pi ni on mate gear shaft from di fferenti al
case (Fi g. 23).
(7) Push axl e shaft i nward and remove axl e shaft
Ccl i p l ock from the axl e shaft (Fi g. 24).
(8) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal , whi ch wi l l remai n i n
axl e shaft tube. Al so, exerci se care not to damage the
wheel speed sensor on vehi cl es equi pped wi th ABS
brakes.
(9) I nspect axl e shaft seal for l eakage or damage.
(10) I nspect rol l er beari ng contact surface on axl e
shaft for si gns of bri nel l i ng, gal l i ng and pi tti ng. I f
any of these condi ti ons exi st, the axl e shaft and/or
beari ng and seal must be repl aced.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip. Also, exercise care not to
damage the wheel speed sensor on vehicles
equipped with ABS brakes
(2) I nsert Ccl i p l ock i n end of axl e shaft. Push
axl e shaft outward to seat Ccl i p l ock i n si de gear.
(3) I nsert pi ni on mate shaft i nto di fferenti al case
and through thrust washers and pi ni on gears.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 19 Nm (14 ft. l bs.)
torque.
(5) I nstal l cover and add fl ui d. Refer to Lubri cant
Change procedure i n thi s secti on for procedure and
l ubri cant requi rements.
(6) I nstal l brake cal i per and rotor. Refer to Group
5, Brakes, for proper procedures.
(7) I nstal l wheel and ti re.
AXLE SHAFT SEAL AND BEARING
REMOVAL
(1) Remove the axl e shaft.
(2) Remove the axl e shaft seal from the end of the
axl e shaft tube wi th a smal l pry bar.
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove the axl e shaft beari ng from the tube
(Fi g. 25) wi th Beari ng Removal Tool Set 6310 usi ng
Adapter Foot 6310-5.
Fig. 24 Axle Shaft CClip Lock
C-CLIPLOCK AXLESHAFT SIDE GEAR
Fig. 25 Axle Shaft Bearing Removal Tool
AXLE SHAFT TUBE NUT GUIDE PLATE GUIDE THREADED ROD ADAPTER FOOT
(4) I nspect the axl e shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
Do not install the original axle shaft seal.
Always install a new seal.
(1) Wi pe the bore i n the axl e shaft tube cl ean.
(2) I nstal l axl e shaft beari ng wi th I nstal l er 6436
and Handl e C4171. Ensure part number on the
beari ng i s agai nst the i nstal l er.
(3) I nstal l the new axl e shaft seal (Fi g. 26) wi th
I nstal l er 6437 and Handl e C4171.
(4) I nstal l the axl e shaft.
DIFFERENTIAL
REMOVAL
(1) Remove axl e shafts.
(2) Note the ori entati on of the i nstal l ati on refer-
ence l etters stamped on the beari ng caps and hous-
i ng machi ned seal i ng surface (Fi g. 27).
(3) Remove the di fferenti al beari ng caps.
(4) Posi ti on Spreader W129B wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 28).
(5) I nstal l the hol d down cl amps and ti ghten the
tool turnbuckl e fi ngerti ght.
the di fferenti al housi ng. Attach di al i ndi cator to
housi ng pi l ot stud. Load the i ndi cator pl unger
agai nst the opposi te si de of the housi ng (Fi g. 28) and
zero the i ndi cator.
(7) Spread the housi ng enough to remove the case
from the housi ng. Measure the di stance wi th the di al
damaged.
(9) Pry the di fferenti al case l oose from the hous-
i ng. To prevent damage, pi vot on housi ng wi th the
end of the pry bar agai nst spreader (Fi g. 29).
(10) Remove the case from housi ng. Mark or tag
beari ng cups and outboard shi m(s)/spacer(s) (sel ected
thi ckness) to i ndi cate whi ch si de they were removed
from.
INSTALLATION
(1) Posi ti on Spreader W129B wi th the tool dowel
hol d down cl amps and ti ghten the tool turnbuckl e
fi ngerti ght.
the di fferenti al housi ng. Attach di al i ndi cator to
housi ng pi l ot stud. Load the i ndi cator pl unger
Fig. 26 Axle Shaft Seal Installation
SPECIAL TOOL 6437 SEAL AXLE SHAFT TUBE SPECIAL TOOL C-4171
Fig. 28 Spread Differential Housing
HOUSING SPREADER W-129B DIAL INDICATOR C-3339 DIFFERENTIAL AXLE HOUSING GUIDE PIN C-3288B
agai nst the opposi te si de of the housi ng (Fi g. 28) and
zero the i ndi cator.
damaged.
(5) I nstal l di fferenti al and outboard shi m(s)/spac-
er(s) (sel ected thi ckness) i n housi ng.
(6) I nstal l case i n the housi ng. Tap the di fferenti al
case wi th a rawhi de or rubber mal l et to ensure the
beari ngs are ful l y seated i n the di fferenti al housi ng
(Fi g. 30).
(7) Remove the spreader.
ti ons (Fi g. 31). Ti ghten the beari ng cap bol ts to 77
(9) I nstal l axl e shafts.
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
wi th Pul l er/Press C-293-PA, Adapters C-293-42, and
Pl ug C-293-3 (Fi g. 32).
INSTALLATION
(1) Usi ng tool C-4340 wi th handl e C-4171, i nstal l
di fferenti al si de beari ngs (Fi g. 33).
RING GEAR
the pi ni on gear.
REMOVAL
case.
Fig. 29 Differential Removal
DIFFERENTIAL PRY BAR
Fig. 30 Differential Installation
RAWHIDE HAMMER
INSTALLATION
hol e al i gnment.
35).
SPECIAL TOOL C-29342 BEARING DIFFERENTIAL SPECIAL TOOL C-2933 SPECIAL TOOL C-293PA
Fig. 33 Install Differential Side Bearings
HANDLE C-4171 DIFFEREN- TIAL BEARING TOOLC-4340
PINION GEAR
NOTE: The ring and pinion gears are service in a
matched set. Do not replace the pinion gear without
replacing the ring gear.
REMOVAL
i ng.
(2) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from pi ni on yoke.
Usi ng sui tabl e wi re, ti e propel l er shaft to underbody.
washer (Fi g. 36).
(5) Usi ng Remover C-452 and Wrench C-3281,
(6) Remove the pi ni on gear from housi ng (Fi g. 38).
Catch the pi ni on wi th your hand to prevent i t from
fal l i ng and bei ng damaged.
(7) Remove the pi ni on seal wi th a sl i de hammer or
pry out wi th bar.
(8) Remove oi l sl i nger, i f equi pped, and the front
pi ni on beari ng.
(9) Remove the front pi ni on beari ng cup wi th
Remover D-103 and Handl e C-4171 (Fi g. 39).
(10) Remove the rear beari ng cup from housi ng
(Fi g. 40). Use Remover C-4307 and Handl e C-4171.
(11) Remove the col l apsi bl e prel oad spacer (Fi g.
41).
1 in. PIPE
PINION YOKE
SPECIAL TOOL 6958
RAWHIDE HAM- MER
REMOVER HANDLE
(12) Remove the rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-42 (Fi g.
42).
the bearing cage.
(13) Remove the pi ni on depth shi ms from the pi n-
i on gear shaft. Record the total thi ckness of the
depth shi ms.
INSTALLATION
(1) Appl y Mopar Door Ease sti ck l ubri cant to out-
si de surface of beari ng cup. I nstal l the pi ni on rear
beari ng cup wi th I nstal l er C-4308 and Dri ver Handl e
C-4171 (Fi g. 43). Ensure cup i s correctl y seated.
(2) Appl y Mopar Door Ease sti ck l ubri cant to out-
si de surface of beari ng cup. I nstal l the pi ni on front
beari ng cup wi th I nstal l er D-129 and Handl e C-4171
(Fi g. 44).
DRIVER HANDLE
Fig. 42 Inner Bearing Removal
Fig. 43 Pinion Rear Bearing Cup Installation
INSTALLER HANDLE
(3) I nstal l pi ni on front beari ng and oi l sl i nger, i f
equi pped. Appl y a l i ght coati ng of gear l ubri cant on
the l i p of pi ni on seal . I nstal l seal wi th I nstal l er
C-3972-A and Handl e C-4171 (Fi g. 45).
rear pinion bearing cone and pinion gear to achieve
ion depth shim should not require replacement or
adjustment. Refer to Pinion Gear Depth paragraph
in this section to select the proper thickness shim
before installing rear pinion bearing cone.
(4) Pl ace the proper thi ckness pi ni on depth shi m
on the pi ni on gear.
(5) I nstal l the rear beari ng (and sl i nger i f used) on
the pi ni on gear wi th I nstal l er 6448 (Fi g. 46).
(7) I nstal l pi ni on gear i n housi ng.
(8) I nstal l yoke wi th I nstal l er C-3718 and hol der
6958 (Fi g. 48).
mi ni mum. Do not over-tighten. Maxi mum torque i s
380 Nm (280 ft. l bs.).
Fig. 44 Pinion Front Bearing Cup Installation
INSTALLER HANDLE
SPECIAL TOOL C-4171
Fig. 46 Shaft Rear Bearing Installation
PRESS INSTALLATION TOOL DRIVE PINION GEAR DRIVE PINION GEAR SHAFT REAR BEARING
decrease pinion gear bearing preload torque and
be installed. The torque sequence will have to be
repeated.
NOTE: If the spacer requires more than 280 ft. lbs.
torque to crush, the collapsible spacer is defective.
l bs.).
(13) Al i gn previ ousl y made marks on yoke and
(14) I nstal l di fferenti al housi ng i nto the axl e hous-
i ng.
FINAL ASSEMBLY
(Fi g. 60).
SPECIAL TOOL C-3718
PINION YOKE
SPECIAL TOOL 6958
1 in. PIPE
DISASSEMBLY
(1) Remove pi ni on gear mate shaft l ock screw (Fi g.
55).
(2) Remove pi ni on gear mate shaft.
(3) Rotate the di fferenti al si de gears and remove
the pi ni on mate gears and thrust washers (Fi g. 56).
washers.
ASSEMBLY
washers.
ers.
(3) I nstal l the pi ni on gear mate shaft.
(4) Al i gn the hol e i n the pi ni on gear mate shaft
wi th the hol e i n the di fferenti al case and i nstal l the
pi ni on gear mate shaft l ock screw.
TRAC-LOK DIFFERENTIAL
The TracLok di fferenti al components are i l l us-
trated i n (Fi g. 54). Refer to thi s i l l ustrati on duri ng
repai r servi ce.
DISASSEMBLY
(1) Cl amp Si de Gear Hol di ng Tool 6963A i n a
vi se.
Hol di ng Tool 6963-A (Fi g. 55).
(3) Remove ri ng gear, i f necessary. Ri ng gear
removal i s necessary onl y i f the ri ng gear i s to be
repl aced. The Trac-Lok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(4) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 56).
(5) Remove the pi ni on gear mate shaft. I f neces-
sary, use a dri ft and hammer (Fi g. 57).
(6) I nstal l and l ubri cate Step Pl ate C44871 (Fi g.
58).
Fig. 52 Pinion Gear Mate Shaft Lock Screw
(7) Assembl e Threaded Adapter C44873 i nto top
si de gear. Thread Forci ng Screw C44872 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(8) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter C44873 (Fi g. 59) to prevent
adapter from turni ng.
(9) Ti ghten forci ng screw tool 122 Nm (90 ft. l bs.)
(maxi mum) to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 60).
(10) Usi ng an appropri ate si ze feel er gauge,
remove thrust washers from behi nd the pi ni on gears
(Fi g. 61).
(11) I nsert Turni ng Bar C44874 i n case (Fi g.
62).
(12) Loosen the Forci ng Screw C-4487-2 i n smal l
i ncrements unti l the cl utch pack tensi on i s rel i eved
and the di fferenti al case can be turned usi ng Turni ng
Bar C-4487-4.
Fig. 54 TracLok Differential Components
THRUST WASHER
PINION
SHAFT LOCK SCREW
Fig. 55 Differential Case Holding Tool
SPECIAL TOOL 6963A
VISE
(13) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(14) Remove pi ni on gears from di fferenti al case.
(15) Remove Forci ng Screw C4487-2, Step Pl ate
(16) Remove top si de gear, cl utch pack retai ner,
removal (Fi g. 63).
(17) Remove di fferenti al case from Si de Gear Hol d-
i ng Tool 6963-A. Remove si de gear, cl utch pack
retai ner, and cl utch pack. Keep pl ates i n correct
order duri ng removal .
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 64).
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 65). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
Fig. 57 Mate Shaft Removal
PINION MATE SHAFT
SIDE GEAR
DRIFT
Fig. 58 Step Plate Tool Installation
LOWER SIDE GEAR
Fig. 59 Threaded Adapter Installation
SOCKET
SLOT IN ADAPTER
SCREWDRIVER
Fig. 60 Tighten Belleville Spring CompressorTool
TORQUE WRENCH TOOL ASSEM- BLED DIFFERENTIAL CASE
Hol di ng Tool 6963-A.
(5) I nstal l l ubri cated Step Pl ate C44871 on si de
gear (Fi g. 66).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 66).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C44873 i nto top si de gear.
(8) I nsert Forci ng Screw C44872.
(9) Ti ghten forci ng screw tool to sl i ghtl y compress
cl utch di scs.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar C44874 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove forci ng screw, threaded adapter, and
step pl ate.
Fig. 61 Remove Pinion Gear Thrust Washer
FEELER GAUGE
THRUST WASHER
Fig. 62 Pinion Gear Removal
PINION GEARS TOOL
Fig. 63 Side Gear & Clutch Disc Removal
DIFFERENTIAL CASE
Fig. 64 Clutch Disc Pack
CLUTCH PACK RETAINER SIDE GEAR RETAINER
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l the pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
If replacement side and/or pinion gears and
thrust washers were installed, it is not neces-
sary to measure the side gear backlash. Correct
fit is due to close machining tolerances during
manufacture.
AXLE COMPONENTS
I nspect for;
faces.
teeth.
TRAC-LOK
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de and pi ni on gears. Repl ace any
gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
PRESOAK PLATES AND DISC
Pl ates and di scs wi th fi ber coati ng (no grooves or
l i nes) must be presoaked i n Fri cti on Modi fi er before
assembl y. Soak pl ates and di scs for a mi ni mum of 20
mi nutes.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
Fig. 65 Clutch Discs & Lower Side GearInstallation
DIFFERENTIAL CASE
LOWER SIDE GEAR AND CLUTCH DISC PACK
Fig. 66 Upper Side Gear & Clutch DiscPack
Installation
UPPER SIDE GEAR AND CLUTCH DISC PACK
DIFFERENTIAL CASE
provi des the best teeth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s Paragraph i n
under the i nner pi ni on beari ng cone (Fi g. 68).
ance charts.
mi nus amount needed.
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0, no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
ADJ USTMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th Pi ni on Gauge Set 6955, Dummy Beari ng/
Arbor Di sc Set 6956, and Di al I ndi cator C-3339 (Fi g.
69).
(Fi g. 69).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght (Fi g. 69).
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons
i n thi s secti on.
NOTE: Arbor Discs 6927 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
fl ush agai nst the surface of the pi ni on hei ght bl ock.
Hol d scooter bl ock i n pl ace and zero the di al i ndi ca-
tor face to the poi nter. Ti ghten di al i ndi cator face
l ock screw.
Observe how many revol uti ons countercl ockwi se the
di al poi nter travel s (approxi matel y 0.125 i n.) to the
out-stop of the di al i ndi cator.
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 72). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
AXLE HOUSING COLLAPSIBLE SPACER PINION BEARING PINION DEPTH SHIM PINIONGEAR BEARING CUP
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
etched i n the face of the pi ni on gear (Fi g. 67) usi ng
the opposi te si gn on the vari ance number. For exam-
pl e, i f the depth vari ance i s 2, add +0.002 i n. to the
di al i ndi cator readi ng.
(10) Remove the pi ni on depth gauge components
from the axl e housi ng
BACKLASH
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the axl e housi ng. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs 6929-A i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on gear for i nstal l ati on. Estab-
l i shi ng proper pi ni on gear depth i s essenti al to estab-
l i shi ng gear backl ash and tooth contact patterns.
After the overal l shi m thi ckness to take up di fferen-
ti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of
the di al i ndi cator readi ng, starti ng poi nt shi m thi ck-
ness, and the prel oad speci fi cati on added together.
The gear backl ash measurement determi nes the
thi ckness of the shi m used on the ri ng gear si de of
sel ect that amount for the pi ni on gear si de of the di f-
ferenti al (Fi g. 73).
DIFFERENTIAL PRELOAD AND GEAR
BACKLASH SHIM SELECTION
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(3) I nstal l dummy si de beari ngs 6929-A on di ffer-
enti al case.
(5) I nsert Dummy Shi m 8107 (0.118 i n. (3.0 mm))
starti ng poi nt shi ms between the dummy beari ng
and the axl e housi ng on si de of di fferenti al (Fi g. 74).
Fig. 74 Preload Measurement Starting PointShim
STARTING POINT SHIM
AXLE HOUSING
DIFFERENTIAL CASE
posi ti ons. I nstal l and snug the bol ts.
(8) Attach di al i ndi cator C-3339 to Gui de Stud
C-3288-B. Posi ti on the di al i ndi cator pl unger on a
fl at surface between the ri ng gear bol t heads (Fi g.
75).
(9) Push and hol d di fferenti al case to pi ni on gear
si de of axl e housi ng.
(13) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
stud.
(16) Remove di fferenti al case, dummy beari ngs,
and starti ng poi nt shi ms from axl e housi ng.
(17) I nstal l pi ni on gear i n axl e housi ng. I nstal l the
yoke and establ i sh the correct pi ni on rotati ng torque.
i n axl e housi ng (wi thout shi ms) and ti ghten retai ni ng
cap bol ts snug.
surface between the ri ng gear bol t heads (Fi g. 75).
gear.
ri ng and pi ni on gears. Thi s total i s the thi ckness of
axl e housi ng.
stud.
(28) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(29) I nstal l spreader W-129-B on axl e housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case and si de beari ng shi ms.
(30) Pl ace si de beari ng shi ms i n axl e housi ng
agai nst axl e tube ends.
(32) Remove spreader from axl e housi ng.
ness from one si de of the axl e housi ng to the other
(Fi g. 77).
After the proper backl ash i s achi eved, perform the
DIFFERENTIAL CASE
AXLE HOUSING
SPECIAL TOOL C-3288B
gear teeth.
pattern.
shop towel .
as necessary.
DIAL INDI- CATOR
DECREASE SHIM THIS
SIDE FOR LESS BACK-
LASH
FOR LESS BACKLASH
FOR LESS BACKLASH
DECREASE SHIM THIS
SIDE FOR MORE BACK-
LASH
SPECIFICATIONS
216 RBA AXLE
DESCRIPTION SPEC.
Type . . . . . . . . . . . . . . . . . . . . Semi -fl oati ng Hypoi d
Axle Ratios . . . . . . . . . . . . . . . . . . . . . . . . 3.55/3.73
Ring Gear Diameter . . . . . . . . . . 216 mm (8.5 i n.)
Gear Backlash . . . 0.130.20 mm (0.0050.008 i n.)
Pinion Depth . . . . . . . . . . . . 109.52 mm (4.312 i n.)
Brg. Preload, Pinion
(New) . . . . . . . . . . 2.264.52 Nm (2040 i n. l bs.)
Brg. Preload, Pinion
(Used) . . . . . . . . . . . . . . 13 Nm (1020 i n. l bs.)
MaximumCarrier Spread . . . 0.51 mm (0.020 i n.
TORQUE
DESCRIPTION TORQUE
Bolts, Diff. Cover . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bolts, Diff. Bearing Cap . . . . . 85 Nm (63 ft. l bs.)
Bolts, Ring Gear . . . . . . . . . . 108 Nm (80 ft. l bs.)
Screw, ABS Sensor . . . . . . . . . . 8 Nm (70 i n. l bs.)
Screw, Pinion Gear Mate
Shaft Lock . . . . . . . . . . . . . 17.6 Nm (13 ft. l bs.)
Nuts, Brake Backing Plate . . . 61 Nm (45 ft. l bs.)
Nut, Pinion
GearMinimum* . . . . . . 298 Nm (220 ft. l bs.)
Nut, Pinion
GearMaximum* . . . . . . 380 Nm (280 ft. l bs.)
NOTE: *Refer to Pinion Gear Removal and Installa-
tion procedures for proper pinion nut tightening
instructions. Do not exceed 380 Nm (280 ft. lbs.)
during collapsible spacer crushing procedure.
SPECIAL TOOLS
216 RBA AXLE
Puller SetC-293-PA
AdapterC-293-42
ExtensionC-293-3
RemoverC-452
HolderC-3281
InstallerC-3718
HandleC-4171
RemoverC-4307
InstallerC-4308
InstallerC-4340
Guide PinC-3288-B
Trac-lok Tool SetC-4487
InstallerC-3972-A
InstallerD-129
RemoverD-103
SpreaderW-129-B
Remover6310
Installer6436
Installer6437
Installer6448
Adapter6790
Pinion Depth Set6955
Adapter Set6956
Gauge Block8144
Starting Point Shim8107
Holder6958
Holder6963-A
Remover7794-A
BRAKES
CONTENTS
page page
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . 35 BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 1
BASE BRAKE SYSTEM
INDEX
page page
GENERAL INFORMATION
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE WARNINGS & CAUTIONS . . . . . . . . . 2
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . 5
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 3
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . 3
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 3
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . 4
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . 2
REAR DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 3
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . 2
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 2
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . 5
BRAKE FLUID CONTAMINATION . . . . . . . . . . . 11
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . 11
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 8
FRONT DISC BRAKE ROTOR . . . . . . . . . . . . . . 9
MASTER CYLINDER/POWER BOOSTER . . . . . . 8
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . 10
REAR DISC BRAKE ROTOR . . . . . . . . . . . . . . 10
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . 8
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . 12
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 11
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DISC ROTOR MACHINING . . . . . . . . . . . . . . . . 13
MASTER CYLINDER BLEEDING . . . . . . . . . . . 11
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . 15
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . 16
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . 19
DISC BRAKE SHOES . . . . . . . . . . . . . . . . . . . . 17
FRONT PARKING BRAKE CABLE . . . . . . . . . . 22
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . 15
PARKING BRAKE CAM AND LEVER . . . . . . . . 24
PARKING BRAKE HAND LEVER . . . . . . . . . . . 22
PARKING BRAKE SHOES . . . . . . . . . . . . . . . . 23
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . 16
REAR DISC BRAKE CALIPER . . . . . . . . . . . . . 19
REAR DISC BRAKE ROTOR . . . . . . . . . . . . . . 21
REAR DISC BRAKE SHOES . . . . . . . . . . . . . . 20
REAR PARKING BRAKE CABLE . . . . . . . . . . . 23
SPLASH SHIELD/CALIPER BRACKET/LEVER
BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 14
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . 28
MASTER CYLINDER RESERVOIR . . . . . . . . . . 27
REAR DISC BRAKE CALIPER . . . . . . . . . . . . . 30
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ADJUSTMENTS
PARKING BRAKE CABLE TENSIONER . . . . . . 32
PARKING BRAKE SHOE . . . . . . . . . . . . . . . . . 33
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 32
SPECIFICATIONS
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . 33
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . 33
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 34
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 34
ZG BRAKES 5 - 1
GENERAL INFORMATION
BRAKE SYSTEM
Al l vehi cl es are equi pped wi th power assi st four-
wheel di sc brakes. Anti l ock (ABS) brakes are al so
standard equi pment on al l model s.
Si ngl e pi ston, di sc brake cal i pers are used front
and rear. Venti l ated di sc brake rotors are used at the
front and sol i d rotors are used at the rear.
Power brake assi st i s suppl i ed by a vacuum oper-
ated, dual di aphragm power brake booster.
The master cyl i nder used for al l appl i cati ons has
an al umi num body and nyl on reservoi r wi th si ngl e
fi l l er cap.
A combi nati on val ve i s used for al l appl i cati ons.
The val ve contai ns a pressure di fferenti al swi tch and
rear brake proporti oni ng val ve.
SERVICE WARNINGS & CAUTIONS
WARNING: FACTORY INSTALLED BRAKE LININGS
DO NOT CONTAIN ASBESTOS FIBERS. DUST AND
DIRT ACCUMULATING ON BRAKE PARTS DURING
NORMAL USE MAY CONTAIN ASBESTOS FIBERS
FROM AFTER MARKET BRAKE LININGS. BREATH-
ING EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT CLEAN BRAKE PARTS WITH COM-
PRESSED AIR OR BY DRY BRUSHING. USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
THE REMOVAL OF ASBESTOS FIBERS FROM
BRAKE COMPONENTS. IF A SUITABLE VACUUM
CLEANER IS NOT AVAILABLE, CLEANING SHOULD
BE DONE WITH A WATER DAMPENED CLOTH. DO
NOT SAND, OR GRIND BRAKE LINING UNLESS
EQUIPMENT USED IS DESIGNED TO CONTAIN THE
DUST RESIDUE. DISPOSE OF ALL RESIDUE CON-
TAINING ASBESTOS FIBERS IN SEALED BAGS OR
CONTAINERS TO MINIMIZE EXPOSURE TO YOUR-
SELF AND OTHERS. FOLLOW PRACTICES PRE-
SCRIBED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION AND THE ENVIRONMEN-
TAL PROTECTION AGENCY FOR THE HANDLING,
PROCESSING, AND DISPOSITION OF DUST OR
DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Drain and
flush the system with new brake fluid if contamina-
tion is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper bushings
and slide pins to ensure proper operation.
BRAKE PEDAL
A suspended-type brake pedal i s used, the pedal
pi vots on a shaft mounted i n the pedal support
bracket. The bracket i s attached to the dash panel .
The brake pedal i s a servi ceabl e component. The
pedal , pedal bushi ngs and shaft are al l repl aceabl e
parts. The pedal bracket can al so be repl aced when
necessary.
STOP LAMP SWITCH
The pl unger type stop l amp swi tch i s mounted on a
bracket attached to the brake pedal support. The
swi tch can be adjusted when necessary.
RED BRAKE WARNING LAMP
A red warni ng l amp i s used for the servi ce brake
porti on of the hydraul i c system. The l amp i s l ocated
i n the i nstrument cl uster.
The red warni ng l i ght al erts the dri ver i f a pres-
sure di fferenti al exi sts between the front and rear
hydraul i c systems. The l i ght al so al erts the dri ver
when the parki ng brakes are appl i ed.
POWER BRAKE BOOSTER
The booster assembl y consi sts of a housi ng di vi ded
i nto separate chambers by two i nternal di aphragms.
The outer edge of each di aphragm i s attached to the
booster housi ng. The di aphragms are connected to
the booster pri mary push rod.
Two push rods are used i n the booster. The pri -
mary push rod connects the booster to the brake
pedal . The secondary push rod connects the booster
to the master cyl i nder to stroke the cyl i nder pi stons.
The atmospheri c i nl et val ve i s opened and cl osed
by the pri mary push rod. Booster vacuum suppl y i s
5 - 2 BRAKES ZG
through a hose attached to an i ntake mani fol d fi tti ng
at one end and to the booster check val ve at the
other. The vacuum check val ve i n the booster housi ng
i s a one-way devi ce that prevents vacuum l eak back.
Power assi st i s generated by uti l i zi ng the pressure
di fferenti al between normal atmospheri c pressure
and a vacuum. The vacuum needed for booster oper-
ati on i s taken di rectl y from the engi ne i ntake mani -
fol d. The entry poi nt for atmospheri c pressure i s
through a fi l ter and i nl et val ve at the rear of the
housi ng (Fi g. 1).
The chamber areas forward of the booster di a-
phragms are exposed to vacuum from the i ntake
mani fol d. The chamber areas to the rear of the di a-
phragms, are exposed to normal atmospheri c pres-
sure of 101.3 ki l opascal s (14.7 pounds/square i n.).
Brake pedal appl i cati on causes the pri mary push
rod to open the atmospheri c i nl et val ve. Thi s exposes
the area behi nd the di aphragms to atmospheri c pres-
sure. The resul ti ng pressure di fferenti al provi des the
extra appl y pressure for power assi st.
MASTER CYLINDER
The master cyl i nder has a removabl e nyl on reser-
voi r. The cyl i nder body i s made of al umi num and
contai ns a pri mary and secondary pi ston assembl y.
The cyl i nder body i ncl udi ng the pi ston assembl i es
are not servi ceabl e. I f di agnosi s i ndi cates an i nternal
probl em wi th the cyl i nder body, i t must be repl aced
as an assembl y. The reservoi r and grommets are the
onl y repl aceabl e parts on the master cyl i nder.
COMBINATION VALVE
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e. I t must be
repl aced i f di agnosi s i ndi cates thi s i s necessary.
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs are
made.
The rear proporti oni ng val ve i s used to bal ance
front-rear brake acti on. The val ve al l ows normal
fl ui d fl ow duri ng moderate effort brake stops. The
val ve onl y control s (meters) fl ui d fl ow duri ng hi gh
effort brake stops.
FRONT DISC BRAKES
The cal i pers are a si ngl e pi ston type. The cal i pers
are free to sl i de l ateral l y, thi s al l ows conti nuous com-
pensati on for l i ni ng wear.
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi ston. The fl ui d pressure
i s exerted equal l y and i n al l di recti ons. Thi s means
pressure exerted agai nst the cal i per pi ston and
wi thi n the cal i per bore wi l l be equal (Fi g. 2).
Fl ui d pressure appl i ed to the pi ston i s transmi tted
di rectl y to the i nboard brake shoe. Thi s forces the
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bore forces the cal i per to sl i de i nward on
the mounti ng bol ts. Thi s acti on bri ngs the outboard
brake shoe l i ni ng i nto contact wi th the outer surface
of the di sc brake rotor.
I n summary, fl ui d pressure acti ng si mul taneousl y
on both pi ston and cal i per, produces a strong cl amp-
i ng acti on. When suffi ci ent force i s appl i ed, fri cti on
wi l l stop the rotors from turni ng and bri ng the vehi -
cl e to a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi ston. Upon rel ease of the pedal , the cal i per and pi s-
ton return to a rest posi ti on. The brake shoes do not
retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal control s the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal i s defl ected out-
ward by fl ui d pressure and pi ston movement (Fi g. 3).
When the brakes (and fl ui d pressure) are rel eased,
the seal rel axes and retracts the pi ston.
The amount of pi ston retracti on i s determi ned by
brake l i ni ng wear. General l y the amount i s just
enough to mai ntai n contact between the pi ston and
i nboard brake shoe.
REAR DISC BRAKES
Rear di sc brake components consi st of si ngl e pi s-
ton, fl oati ng-type, rear di sc brake cal i pers and sol i d
rotors.
The rear cal i pers are mounted i n a bracket
attached to the rear axl e tube fl ange (Fi g. 4). The
cal i pers are secured to the bracket wi th mounti ng
bol ts. The bracket al so secures the rear di sc brake
rotor spl ash shi el d to the tube fl ange.
The rotor and spl ash shi el d used for rear di sc
brake appl i cati ons are uni que. The parki ng brake
shoes are mounted on the spl ash shi el d. The di sc
brake rotor has a bui l t i n brake drum surface for the
ZG BRAKES 5 - 3
parki ng brake shoes (Fi g. 5). Parki ng brake shoe ser-
vi ce i s covered i n the parki ng brake servi ce secti on.
The outboard shoe now has an anti -rattl e spri ng
attached at the shoe rear. A wear stri p i s mounted to
the i nboard shoe.
PARKING BRAKES
The parki ng brakes are operated by a cabl e and
hand l ever system. Three cabl es are used, consi sti ng
of one front cabl e and two rear cabl es. Al l three
cabl es are i nterconnected at the cabl e tensi oner and
equal i zer mechani sm. The front cabl e i s connected to
the hand l ever and the rear cabl es are connected to
the brake shoes. Cabl e adjustment i s performed at
the tensi oner whi ch i s attached to the front cabl e.
A separate set of brake shoes are used for parki ng
brake operati on. The shoes are mounted on the di sc
brake spl ash shi el d and are encl osed wi thi n the com-
bi nati on di sc brake rotor and parki ng brake drum.
The rear cabl es are connected to a cam and l ever
mechani sm, the cam and l ever operates the shoes.
The cabl e i s connected to the l ever by a rectangu-
l ar eyel et on the cabl e end. A retai ner on the cabl e
secures i t i n a bracket attached to the rear of the cal -
i per bracket. The l ever i s mounted on the fl oorpan
adjacent to the dri ver.
NOTE: Parking brake cable adjustment is con-
trolled by a tensioner mechanism. The cable ten-
sioner, once adjusted at the factory, will not need
further adjustment under normal circumstances.
There are only time a adjustment is required is
when the tensioner, or cables have been replaced
or disconnected.
Fig. 1 Power Brake BoosterTypical
VACUUM CHECK VALVE FRONT DIA- PHRAGM REAR DIA- PHRAGM HOUSING SEAL AIR FILTER PRIMARY PUSH ROD (TO BRAKE PEDAL) ATMOSPHERIC INLET VALVE ASSEMBLY BOOSTER MOUNTING STUDS (4) SECONDARY PUSH ROD (TO MASTER CYLINDER) MASTER CYLINDER MOUNTING STUD (2) SPRING
5 - 4 BRAKES ZG
BRAKE HOSES AND LINES
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. Doubl e wal l ed
steel tubi ng i s used to connect the master cyl i nder to
the major hydraul i c braki ng components and then to
the fl exi bl e rubber hoses.
BASE BRAKE SYSTEM
Base brake components consi st of the brake shoes,
cal i pers, wheel cyl i nders, brake drums, rotors, brake
l i nes, master cyl i nder, booster, and parki ng brake
components.
Brake di agnosi s i nvol ves determi ni ng i f the prob-
l em i s rel ated to a mechani cal , hydraul i c, or vacuum
operated component.
The fi rst di agnosi s step i s the prel i mi nary check.
PRELIMINARY BRAKE CHECK
(1) Check condi ti on of ti res and wheel s. Damaged
wheel s and worn, damaged, or underi nfl ated ti res
can cause pul l , shudder, vi brati on, and a condi ti on
si mi l ar to grab.
(2) I f compl ai nt was based on noi se when braki ng,
check suspensi on components. Jounce front and rear
of vehi cl e and l i sten for noi se that mi ght be caused
by l oose, worn or damaged suspensi on or steeri ng
components.
(3) I nspect brake fl ui d l evel and condi ti on. Note
that the front di sc brake reservoi r fl ui d l evel wi l l
decrease i n proporti on to normal l i ni ng wear. Also
note that brake fluid tends to darken over time.
This is normal and should not be mistaken for
contamination.
(a) I f fl ui d l evel i s abnormal l y l ow, l ook for evi -
dence of l eaks at cal i pers, wheel cyl i nders, brake
l i nes, and master cyl i nder.
(b) I f fl ui d appears contami nated, drai n out a
sampl e. System wi l l have to be fl ushed i f fl ui d i s
Fig. 2 Brake Caliper Operation
CALIPER PISTON PISTON BORE SEAL INBOARDSHOE OUTBOARDSHOE
Fig. 3 Lining Wear Compensation By PistonSeal
PISTON CYLINDER BORE PISTON SEAL BRAKE PRES- SURE OFF CALIPER HOUSING DUST BOOT PISTON SEAL BRAKE PRESSURE ON
Fig. 4 Rear Disc Brake Caliper Mounting
SOLID (NON-VENTILATED) ROTOR AND DRUM ASSEMBLY CALIPER MOUNTING BRACKET REAR CALIPER
Fig. 5 Rear Disc Brake Rotor
PARKING BRAKE DRUM SURFACE REAR DISC BRAKE ROTOR
ZG BRAKES 5 - 5
separated i nto l ayers, or contai ns a substance
other than brake fl ui d. The system seal s and cups
wi l l al so have to be repl aced after fl ushi ng. Use
cl ean brake fl ui d to fl ush the system.
(4) Check parki ng brake operati on. Veri fy free
movement and ful l rel ease of cabl es and pedal . Al so
note i f vehi cl e was bei ng operated wi th parki ng
brake parti al l y appl i ed.
(5) Check brake pedal operati on. Veri fy that pedal
does not bi nd and has adequate free pl ay. I f pedal
l acks free pl ay, check pedal and power booster for
bei ng l oose or for bi nd condi ti on. Do not road test
unti l condi ti on i s corrected.
(6) I f components checked appear OK, road test
the vehi cl e.
ROAD TESTING
(1) I f compl ai nt i nvol ved l ow brake pedal , pump
pedal and note i f i t comes back up to normal hei ght.
(2) Check brake pedal response wi th transmi ssi on
i n Neutral and engi ne runni ng. Pedal shoul d remai n
fi rm under constant foot pressure.
(3) Duri ng road test, make normal and fi rm brake
stops i n 25-40 mph range. Note faul ty brake opera-
ti on such as l ow pedal , hard pedal , fade, pedal pul sa-
ti on, pul l , grab, drag, noi se, etc.
PEDAL FALLS AWAY
A brake pedal that fal l s away under steady foot
pressure i s general l y the resul t of a system l eak. The
l eak poi nt coul d be at a brake l i ne, fi tti ng, hose, or
cal i per/wheel cyl i nder. I nternal l eakage i n the master
cyl i nder caused by worn or damaged pi ston cups,
may al so be the probl em cause.
I f l eakage i s severe, fl ui d wi l l be evi dent at or
around the l eaki ng component. However, i nternal
l eakage i n the master cyl i nder may not be physi cal l y
evi dent.
LOW PEDAL
I f a l ow pedal i s experi enced, pump the pedal sev-
eral ti mes. I f the pedal comes back up worn l i ni ngs,
rotors, drums, or rear brakes out of adjustment are
the most l i kel y causes.
SPONGY PEDAL
A spongy pedal i s most often caused by ai r i n the
system. However, thi n brake drums or substandard
brake l i nes and hoses can al so cause a spongy pedal .
The proper course of acti on i s to bl eed the system, or
repl ace thi n drums and suspect qual i ty brake l i nes
and hoses.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or hi gh pedal effort may be due to
l i ni ng that i s water soaked, contami nated, gl azed, or
badl y worn. The power booster or check val ve coul d
al so be faul ty.
PEDAL PULSATION
Pedal pul sati on i s caused by components that are
l oose, or beyond tol erance l i mi ts.
The pri mary cause of pul sati on are di sc brake
rotors wi th excessi ve l ateral runout or thi ckness vari -
ati on, or out of round brake drums. Other causes are
l oose wheel beari ngs or cal i pers and worn, damaged
ti res.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the l i ni ng i s i n constant
contact wi th the rotor or drum. Drag can occur at one
wheel , al l wheel s, fronts onl y, or rears onl y.
Drag i s a product of i ncompl ete brake shoe rel ease.
Drag can be mi nor or severe enough to overheat the
l i ni ngs, rotors and drums.
Mi nor drag wi l l usual l y cause sl i ght surface char-
ri ng of the l i ni ng. I t can al so generate hard spots i n
rotors and drums from the overheat-cool down pro-
cess. I n most cases, the rotors, drums, wheel s and
ti res are qui te warm to the touch after the vehi cl e i s
stopped.
Severe drag can char the brake l i ni ng al l the way
through. I t can al so di stort and score rotors and
drums to the poi nt of repl acement. The wheel s, ti res
and brake components wi l l be extremel y hot. I n
severe cases, the l i ni ng may generate smoke as i t
chars from overheati ng.
Common causes of brake drag are:
Sei zed or i mproperl y adjusted parki ng brake
cabl es.
Loose/worn wheel beari ng.
Sei zed cal i per or wheel cyl i nder pi ston.
Cal i per bi ndi ng on corroded bushi ngs or rusted
sl i de surfaces.
Loose cal i per mounti ng.
Drum brake shoes bi ndi ng on worn/damaged
support pl ates.
Mi sassembl ed components.
I f brake drag occurs at al l wheel s, the probl em
may be rel ated to a bl ocked master cyl i nder return
port, or faul ty power booster (bi nds-does not rel ease).
BRAKE FADE
Brake fade i s usual l y a product of overheati ng
caused by brake drag. However, brake overheati ng
and resul ti ng fade can al so be caused by ri di ng the
brake pedal , maki ng repeated hi gh decel erati on stops
i n a short ti me span, or constant braki ng on steep
5 - 6 BRAKES ZG
mountai n roads. Refer to the Brake Drag i nformati on
i n thi s secti on for causes.
BRAKE PULL
Front brake pul l condi ti on coul d resul t from:
Contami nated l i ni ng i n one cal i per
Sei zed cal i per pi ston
Bi ndi ng cal i per
Loose cal i per
Rusty adapter/cal i per sl i de surfaces
I mproper brake shoes
Damaged rotor
A worn, damaged wheel beari ng or suspensi on
component are further causes of pul l . A damaged
front ti re (brui sed, pl y separati on) can al so cause
pul l .
A common and frequentl y mi sdi agnosed pul l condi -
ti on i s where di recti on of pul l changes after a few
stops. The cause i s a combi nati on of brake drag fol -
l owed by fade at one of the brake uni ts.
As the draggi ng brake overheats, effi ci ency i s so
reduced that fade occurs. Si nce the opposi te brake
uni t i s sti l l functi oni ng normal l y, i ts braki ng effect i s
magni fi ed. Thi s causes pul l to swi tch di recti on i n
favor of the normal l y functi oni ng brake uni t.
An addi ti onal poi nt when di agnosi ng a change i n
pul l condi ti on concerns brake cool down. Remember
that pul l wi l l return to the ori gi nal di recti on, i f the
draggi ng brake uni t i s al l owed to cool down (and i s
not seri ousl y damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pul l i s usual l y caused by i mproperl y
adjusted or sei zed parki ng brake cabl es, contami -
nated l i ni ng, bent or bi ndi ng shoes and support
pl ates, or i mproperl y assembl ed components. Thi s i s
parti cul arl y true when onl y one rear wheel i s
i nvol ved. However, when both rear wheel s are
affected, the master cyl i nder, proporti oni ng val ve, or
RWAL val ve coul d be at faul t.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Thi s condi ti on i s general l y caused by water soaked
l i ni ng. I f the l i ni ng i s onl y wet, i t can be dri ed by
dri vi ng wi th the brakes very l i ghtl y appl i ed for a
mi l e or two. However, i f the l i ni ng i s both soaked and
di rt contami nated, cl eani ng and/or repl acement wi l l
be necessary.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to l i ni ngs that
are wet or contami nated wi th brake fl ui d, grease, or
oi l . Gl azed l i ni ngs and rotors wi th hard spots can
al so contri bute to squeak. Di rt and forei gn materi al
embedded i n the brake l i ni ng wi l l al so cause squeak/
squeal .
A very l oud squeak or squeal i s frequentl y a si gn of
severel y worn brake l i ni ng. I f the l i ni ng has worn
through to the brake shoes i n spots, metal -to-metal
contact occurs. I f the condi ti on i s al l owed to conti nue,
rotors and drums can become so scored that repl ace-
ment i s necessary.
BRAKE CHATTER
Brake chatter i s usual l y caused by l oose or worn
components, or gl azed/burnt l i ni ng. Rotors wi th hard
spots can al so contri bute to chatter. Addi ti onal causes
of chatter are out-of-tol erance rotors, brake l i ni ng not
securel y attached to the shoes, l oose wheel beari ngs
and contami nated brake l i ni ng.
THUMP/CLUNK NOISE
Thumpi ng or cl unk noi ses duri ng braki ng are fre-
quentl y not caused by brake components. I n many
cases, such noi ses are caused by l oose or damaged
steeri ng, suspensi on, or engi ne components. However,
cal i pers that bi nd on the sl i de surfaces can generate
a thump or cl unk noi se. I n addi ti on, worn out,
i mproperl y adjusted, or i mproperl y assembl ed rear
brake shoes can al so produce a thump noi se.
BRAKE LINING CONTAMINATION
Brake l i ni ng contami nati on i s mostl y a product of
l eaki ng cal i pers or wheel cyl i nders, worn seal s, dri v-
i ng through deep water puddl es, or l i ni ng that has
become covered wi th grease and gri t duri ng repai r.
Contami nated l i ni ng shoul d be repl aced to avoi d fur-
ther brake probl ems.
WHEEL AND TIRE PROBLEMS
Some condi ti ons attri buted to brake components
may actual l y be caused by a wheel or ti re probl em.
A damaged wheel can cause shudder, vi brati on and
pul l . A worn or damaged ti re can al so cause pul l .
Severel y worn ti res wi th very l i ttl e tread l eft can
produce a grab-l i ke condi ti on as the ti re l oses and
recovers tracti on. Fl at-spotted ti res can cause vi bra-
ti on and generate shudder duri ng brake operati on. A
ti re wi th i nternal damage such as a severe brui se,
cut, or pl y separati on can cause pul l and vi brati on.
STOP LAMP SWITCH
Stop l amp swi tch operati on can be tested wi th an
ohmmeter. The ohmmeter i s used to check conti nui ty
between the pi n termi nal s at di fferent pl unger posi -
ti ons (Fi g. 6).
NOTE: The switch wire harness must be discon-
nected before testing switch continuity.
ZG BRAKES 5 - 7
SWITCH CIRCUIT IDENTIFICATION
Termi nal s 1 and 2 are for brake sensor ci rcui t.
Termi nal s 5 and 6 are for the stop l amp ci rcui t.
Termi nal s 3 and 4 are for the speed control ci r-
cui t.
SWITCH CONTINUITY TEST
(1) Check conti nui ty between termi nal pi ns 5 and
6 as fol l ows:
(a) Pul l pl unger al l the way out to ful l y extended
posi ti on.
(b) Attach test l eads to pi ns 5 and 6 and note
ohmmeter readi ng.
(c) I f conti nui ty exi sts, proceed to next test.
Repl ace swi tch i f meter i ndi cates l ack of conti nui ty
(shorted or open).
(2) Check conti nui ty between termi nal pi ns 1 and
2 and pi ns 3 and 4 as fol l ows:
(a) Push swi tch pl unger i nward to ful l y
retracted posi ti on.
(b) Attach test l eads to pi ns 1 and 2 and note
ohmmeter readi ng.
(c) I f conti nui ty exi sts, swi tch i s OK. Repl ace
swi tch i f meter i ndi cates l ack of conti nui ty (swi tch
i s open).
RED BRAKE WARNING LAMP
The red warni ng l amp i l l umi nates when the park-
i ng brakes are appl i ed and when there i s a l eak i n
the front or rear wheel brake hydraul i c ci rcui t. I t wi l l
al so i l l umi nate at startup as part of a bul b check.
I f the l i ght comes on, fi rst veri fy that the parki ng
brakes are ful l y rel eased. Then check pedal acti on
and fl ui d l evel . I f a probl em i s confi rmed, i nspect the
brake hydraul i c system for l eaks.
MASTER CYLINDER/POWER BOOSTER
(1) Start engi ne and check booster vacuum hose
connecti ons. A hi ssi ng noi se i ndi cates vacuum l eak.
Correct any vacuum l eak before proceedi ng.
(2) Stop engi ne and shi ft transmi ssi on i nto Neu-
tral .
(3) Pump brake pedal unti l al l vacuum reserve i n
booster i s depl eted.
(4) Press and hol d brake pedal under l i ght foot
pressure. The pedal shoul d hol d fi rm, i f the pedal
fal l s away master cyl i nder i s faul ty (i nternal l eak-
age).
(5) Start engi ne and note pedal acti on i t shoul d
fal l away sl i ghtl y under l i ght foot pressure then hol d
fi rm. I f no pedal acti on i s di scerni bl e, power booster,
vacuum suppl y, or vacuum check val ve i s faul ty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebui l d booster vacuum reserve as fol l ows:
Rel ease brake pedal . I ncrease engi ne speed to 1500
rpm, cl ose the throttl e and i mmedi atel y stop turn off
i gni ti on to stop engi ne.
(7) Wai t a mi ni mum of 90 seconds and try brake
acti on agai n. Booster shoul d provi de two or more vac-
uum assi sted pedal appl i cati ons. I f vacuum assi st i s
not provi ded, booster i s faul ty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check val ve
wi th short l ength of hose and T-fi tti ng (Fi g. 7).
(2) Start and run engi ne at curb i dl e speed for one
mi nute.
(3) Observe the vacuum suppl y. I f vacuum suppl y
i s not adequate, repai r vacuum suppl y.
(4) Cl amp hose shut between vacuum source and
check val ve.
(5) Stop engi ne and observe vacuum gauge.
(6) I f vacuum drops more than one i nch HG (33
mi l l i bars) wi thi n 15 seconds, booster di aphragm or
check val ve i s faul ty.
POWER BOOSTER CHECK VALVE TEST
(1) Di sconnect vacuum hose from check val ve.
(2) Remove check val ve and val ve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Appl y 15-20 i nches vacuum at l arge end of
check val ve (Fi g. 8).
(5) Vacuum shoul d hol d steady. I f gauge on pump
i ndi cates vacuum l oss, check val ve i s faul ty and
shoul d be repl aced.
COMBINATION VALVE
Metering Valve
Meteri ng val ve operati on can be checked vi sual l y
wi th the ai d of a hel per. Observe the meteri ng val ve
stem whi l e a hel per appl i es and rel eases the brakes.
I f the val ve i s operati ng correctl y, the stem wi l l
extend sl i ghtl y when the brakes are appl i ed and
retract when the brakes are rel eased. I f the val ve i s
Fig. 6 Stop Lamp Switch Terminal Identification
TERMINAL PINS PLUNGER TEST POSITIONS
5 - 8 BRAKES ZG
faul ty, repl ace the enti re combi nati on val ve as an
assembl y.
Pressure Differential Switc h
(1) Have hel per si t i n dri vers seat to appl y brake
pedal and observe red brake warni ng l i ght.
(2) Rai se vehi cl e on hoi st.
(3) Connect bl eed hose to a rear wheel cyl i nder
and i mmerse hose end i n contai ner parti al l y fi l l ed
wi th brake fl ui d.
(4) Have hel per press and hol d brake pedal to fl oor
and observe warni ng l i ght.
(a) I f warni ng l i ght i l l umi nates, swi tch i s operat-
i ng correctl y.
(b) I f l i ght fai l s to i l l umi nate, check ci rcui t fuse,
bul b, and wi ri ng. The parki ng brake swi tch can be
used to ai d i n i denti fyi ng whether or not the brake
l i ght bul b and fuse i s functi onal . Repai r or repl ace
parts as necessary and test di fferenti al pressure
swi tch operati on agai n.
(5) I f warni ng l i ght sti l l does not i l l umi nate,
swi tch i s faul ty. Repl ace combi nati on val ve assembl y,
bl eed brake system and veri fy proper swi tch and
val ve operati on.
FRONT DISC BRAKE ROTOR
ROTOR MINIMUM THICKNESS
Rotor mi ni mum usabl e thi ckness i s 22.7 mm (0.89
i n.). Do not resurface a rotor i f machi ni ng woul d
cause thi ckness to fal l bel ow thi s l i mi t.
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f refi ni shi ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
FRONT ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Measure rotor thi ckness at four to si x poi nts
around the rotor face. Posi ti on the mi crometer
approxi matel y 3/4 i nch from the rotor outer ci rcum-
ference for each measurement (Fi g. 9).
Thi ckness shoul d not vary by more than 0.013 mm
(0.0005 i n.) from poi nt to poi nt on the rotor. Refi ni sh
or repl ace the rotor i f necessary.
FRONT ROTOR LATERAL RUNOUT
Check rotor l ateral runout whenever pedal pul sa-
ti on, or rapi d, uneven brake l i ni ng wear has
occurred.
The rotor must be securel y cl amped to the hub to
ensure an accurate runout measurement. Secure the
Fig. 7 Typical Booster Vacuum Test Connections
TEE FITTINGSHORT CONNECTING HOSE CHECK VALVE CHECK VALVE HOSE CLAMPTOOL INTAKE MANI- FOLD VACUUM GAUGE
Fig. 8 Vacuum Check Valve And Seal
BOOSTER CHECK VALVE APPLY TEST VACUUM HERE VALVE SEAL
Fig. 9 Measuring Rotor Thickness Variation
MICROMETER TAKE MINIMUM OF 6 MEASUREMENTS AROUND ROTOR ROTOR
ZG BRAKES 5 - 9
rotor wi th the wheel nuts and 4 or 5 l arge di ameter
fl at washers on each stud.
Use a di al i ndi cator to check l ateral runout (Fi g.
10).
Maxi mum al l owabl e rotor l ateral runout i s 0.13
mm (0.005 i n.).
REAR DISC BRAKE ROTOR
ROTOR MINIMUM THICKNESS
Mi ni mum usabl e thi ckness of the rear di sc brake
rotor i s 9.5 mm (0.374 i n.). The thi ckness speci fi ca-
ti on i s l ocated on the edge of the parki ng brake drum
secti on of the rotor (Fi g. 11).
Never resurface a rotor i f machi ni ng woul d cause
thi ckness to fal l bel ow thi s l i mi t.
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f refi ni shi ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
REAR ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Measure rotor thi ckness at four to si x poi nts
around the rotor face. Posi ti on the mi crometer
approxi matel y 3/4 i nch from the rotor outer ci rcum-
ference for each measurement (Fi g. 9).
Thi ckness shoul d not vary by more than 0.0254
mm (0.001 i n.) from poi nt to poi nt on the rotor.
Refi ni sh or repl ace the rotor i f necessary.
REAR ROTOR LATERAL RUNOUT
Check rotor l ateral runout whenever di agnosi s
i ndi cates pedal pul sati on and rapi d, uneven brake
l i ni ng wear.
The rotor must be securel y cl amped to the hub to
ensure an accurate runout measurement. Secure the
rotor wi th the wheel nuts and 4 or 5 l arge di ameter
fl at washers on each stud.
Use a di al i ndi cator to check l ateral runout (Fi g.
10). Maxi mum al l owabl e l ateral runout i s 0.13 mm
(0.005 i n.).
PARKING BRAKE
NOTE: Parking brake adjustment is controlled by a
cable tensioner. Once the tensioner is adjusted at
the factory, it should not require further attention.
However, there are two instances when adjustment
will be required. The first is when a new tensioner,
or cables have been installed. And the second, is
when the tensioner and cables are disconnected for
access to other brake components.
The parki ng brake swi tch i s i n ci rcui t wi th the red
warni ng l amp i n the dash. The swi tch wi l l cause the
l amp to i l l umi nate onl y when the parki ng brakes are
appl i ed. I f the l amp remai ns on after parki ng brake
rel ease, the swi tch or wi res are faul ty, or cabl e ten-
si oner adjustment i s i ncorrect.
I f the red l amp comes on whi l e the vehi cl e i s i n
moti on and brake pedal hei ght decreases, a faul t has
occurred i n the front or rear brake hydraul i c system.
I n most cases, the actual cause of an i mproperl y
functi oni ng parki ng brake (too l oose/too ti ght/wont
hol d), can be traced to a parki ng brake component.
NOTE: The leading cause of improper parking
brake operation, is excessive clearance between the
parking brake shoes and the shoe braking surface.
Excessive clearance is a result of lining and/or
drum wear, drum surface machined oversize, or
inoperative adjuster components.
Excessi ve parki ng brake l ever travel (someti mes
descri bed as a l oose l ever or too l oose condi ti on), i s
Fig. 10 Checking Rotor Lateral Runout
DIAL INDICATOR
Fig. 11 Thickness Specification On Rear Rotor
LOCATION OF REAR ROTOR MINIMUM THICKNESS SPECIFI- CATION
5 - 10 BRAKES ZG
the resul t of worn brake shoes, i mproper brake shoe
adjustment, or i mproperl y assembl ed brake parts.
A too l oose condi ti on can al so be caused by i nop-
erati ve or i mproperl y assembl ed parki ng brake shoe
parts.
A condi ti on where the parki ng brakes do not hol d,
wi l l most probabl y be due to a wheel brake compo-
nent.
I tems to l ook for when di agnosi ng a parki ng brake
probl em, are:
Rear brake shoe wear
Drum surface (i n rear rotor) machi ned oversi ze
Front cabl e not secured to l ever
Rear cabl e not attached to l ever
Rear cabl e sei zed
Parki ng shoes reversed
Parki ng brake strut not seated i n shoes
Parki ng brake l ever not seated
Parki ng brake l ever bi nd
Cam and l ever worn or mi sassembl ed
Adjuster screws sei zed
Adjuster screws reversed
Parki ng brake adjustment and parts repl acement
procedures are descri bed i n the Parki ng Brake sec-
ti on.
BRAKE LINE AND HOSES
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. I nspect the hoses
whenever the brake system i s servi ced, at every
engi ne oi l change, or whenever the vehi cl e i s i n for
servi ce.
I nspect the hoses for surface cracki ng, scuffi ng, or
worn spots. Repl ace any brake hose i mmedi atel y i f
the fabri c casi ng of the hose i s exposed due to cracks
or abrasi ons.
Al so check brake hose i nstal l ati on. Faul ty i nstal l a-
ti on can resul t i n ki nked, twi sted hoses, or contact
wi th the wheel s and ti res or other chassi s compo-
nents. Al l of these condi ti ons can l ead to scuffi ng,
cracki ng and eventual fai l ure.
The steel brake l i nes shoul d be i nspected peri odi -
cal l y for evi dence of corrosi on, twi sts, ki nks, l eaks, or
other damage. Heavi l y corroded l i nes wi l l eventual l y
rust through causi ng l eaks. I n any case, corroded or
damaged brake l i nes shoul d be repl aced.
Factory repl acement brake l i nes and hoses are rec-
ommended to ensure qual i ty, correct l ength and supe-
ri or fati gue l i fe. Care shoul d be taken to make sure
that brake l i ne and hose mati ng surfaces are cl ean
and free from ni cks and burrs. Al so remember that
ri ght and l eft brake hoses are not i nterchangeabl e.
Use new copper seal washers at al l cal i per connec-
ti ons. Be sure brake l i ne connecti ons are properl y
made (not cross threaded) and ti ghtened to recom-
mended torque.
BRAKE FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
SERVICE PROCEDURES
BRAKE FLUID LEVEL
Al ways cl ean the master cyl i nder reservoi r and cap
before addi ng fl ui d. Thi s wi l l prevent di rt from fal l -
i ng i n the reservoi r and contami nati ng the brake
fl ui d.
The reservoi r has a ADD and a FULL mark on the
si de (Fi g. 12) fi l l to the FULL mark.
MASTER CYLINDER BLEEDING
A new master cyl i nder shoul d be bl ed before i nstal -
l ati on on the vehi cl e. Requi red bl eedi ng tool s i ncl ude
bl eed tubes and a wood dowel to stroke the pi stons.
Bl eed tubes can be fabri cated from brake l i ne.
BLEEDING PROCEDURE
(1) Mount master cyl i nder i n vi se.
(2) Attach bl eed tubes to cyl i nder outl et ports.
Then posi ti on each tube end i n matchi ng reservoi r
fl ui d compartment (Fi g. 13).
Fig. 12 Master Cylinder Fluid Level
FLUID LEVEL MARKS RESERVOIR
ZG BRAKES 5 - 11
NOTE: If master cylinders has one reservoir open-
ing, position both bleed tubes into the single reser-
voir opening (Fig. 14).
(3) Fi l l reservoi r wi th fresh brake fl ui d.
(4) Press cyl i nder pi stons i nward wi th wood dowel .
Then rel ease pi stons and al l ow them to return under
spri ng pressure. Conti nue bl eedi ng operati ons unti l
ai r bubbl es are no l onger vi si bl e i n fl ui d.
BRAKE BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Do not pump the brake pedal at any ti me whi l e
bl eedi ng. Ai r i n the system wi l l be compressed i nto
smal l bubbl es that are di stri buted throughout the
hydraul i c system. Thi s wi l l make addi ti onal bl eedi ng
operati ons necessary.
Do not al l ow the master cyl i nder to run out of fl ui d
duri ng bl eed operati ons. An empty cyl i nder wi l l al l ow
addi ti onal ai r to be drawn i nto the system. Check the
cyl i nder fl ui d l evel frequentl y and add fl ui d as
needed.
Bl eed onl y one brake component at a ti me. Recom-
mended bl eed sequence i s:
master cyl i nder
combi nati on val ve
ri ght rear wheel
l eft rear wheel
ri ght front wheel
l eft front wheel
MANUAL BLEEDING
(1) Remove reservoi r fi l l er caps and fi l l reservoi r
wi th Mopar, or equi val ent qual i ty DOT 3 brake fl ui d.
(2) I f cal i pers, or wheel cyl i nders were overhaul ed,
open al l cal i per and wheel cyl i nder bl eed screws.
Then cl ose each bl eed screw as fl ui d starts to dri p
from i t. Top off master cyl i nder reservoi r once more
before proceedi ng.
(3) Attach one end of bl eed hose to bl eed screw
and i nsert opposi te end i n gl ass contai ner parti al l y
fi l l ed wi th brake fl ui d (Fi g. 15). Be sure end of bl eed
hose i s i mmersed i n fl ui d.
(4) Open up bl eeder, then have a hel per press
down the brake pedal . Once the pedal i s down cl ose
the bl eeder. Repeat bl eedi ng unti l fl ui d stream i s
cl ear and free of bubbl es. Then move to the next
wheel .
PRESSURE BLEEDING
I f pressure bl eedi ng equi pment wi l l be used, the
front brake meteri ng val ve wi l l have to be hel d open
to bl eed the front brakes. The val ve stem i s l ocated
i n the forward end of the combi nati on val ve. The
Fig. 13 Master Cylinder Bleeding
BLEEDING TUBES MASTER CYLINDER HOUSING DOWEL
Fig. 14 Master Cylinder Bleeding
BLEEDING TUBES
RESERVOIR
Fig. 15 Bleed Hose Setup
BLEED HOSE FLUID CON- TAINER PAR- TIALLY FILLED WITH FLUID
5 - 12 BRAKES ZG
stem must ei ther be pressed i nward, or hel d outward
sl i ghtl y. a spri ng cl i p tool or hel per i s needed to hol d
the val ve stem i n posi ti on.
Fol l ow the manufacturers i nstructi ons careful l y
when usi ng pressure equi pment. Do not exceed the
tank manufacturers pressure recommendati ons. Gen-
eral l y, a tank pressure of 15-20 psi i s suffi ci ent for
bl eedi ng.
Fi l l the bl eeder tank wi th recommended fl ui d and
purge ai r from the tank l i nes before bl eedi ng.
Do not pressure bl eed wi thout a proper master cyl -
i nder adapter. The wrong adapter can l ead to l eak-
age, or drawi ng ai r back i nto the system.
DISC ROTOR MACHINING
Rotor braki ng surfaces can be sanded or machi ned
i n a di sc brake l athe.
The l athe must machi ne both si des of the rotor
si mul taneousl y wi th dual (two) cutter heads (Fi g.
16). Equi pment capabl e of machi ni ng onl y one si de at
a ti me wi l l produce a tapered rotor.
The l athe shoul d al so be equi pped wi th a gri nder
attachment or dual sandi ng di scs for fi nal cl eanup or
l i ght refi ni shi ng (Fi g. 17).
I f the rotor surfaces onl y need mi nor cl eanup of
rust, scal e, or mi nor scori ng, use abrasi ve di scs to
cl ean up the rotor surfaces. However, when a rotor i s
scored or worn, machi ni ng wi th cutti ng tool s wi l l be
requi red.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum allowable thick-
ness.
BRAKE LINE
Mopar preformed metal brake l i ne i s recommended
and preferred for al l repai rs. However, doubl e-wal l
steel l i ne can be used for emergency repai r when fac-
tory repl acement parts are not readi l y avai l abl e.
Speci al , heavy duty tube bendi ng and fl ari ng
equi pment i s requi red to prepare doubl e wal l brake
l i ne. Speci al bendi ng tool s are needed to avoi d ki nk-
i ng or twi sti ng metal brake l i ne. I n addi ti on, speci al
fl ari ng tool s are needed to provi de the i nverted-type,
doubl e fl are requi red on metal brake l i nes.
FLARING PROCEDURE
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Ream cut edges of tubi ng to ensure proper
fl are.
(3) I nstal l repl acement tube nut on secti on of tube
to be repai red.
(4) I nsert tube i n fl ari ng tool . Center tube i n area
between verti cal posts.
(5) Pl ace gauge form over the end of the tube.
(6) Push tubi ng through fl ari ng tool jaws unti l
tube contacts recessed notch i n gauge that matches
tube di ameter.
(7) Squeeze fl ari ng tool jaws to l ock tubi ng i n
pl ace.
(8) I nsert pl ug on gauge i n the tube. Then swi ng
compressi on di sc over gauge and center tapered fl ar-
i ng screw i n recess of compressi on di sc (Fi g. 18).
Fig. 16 Rotor Refinishing
BRAKING DISC DAMPER CUTTING TOOLS
Fig. 17 Rotor Grinder
BRAKING DISC GRINDER
ZG BRAKES 5 - 13
(9) Ti ghten tool handl e unti l pl ug gauge i s seated
on jaws of fl ari ng tool . Thi s wi l l start the i nverted
fl are.
(10) Remove the pl ug gauge and compl ete the
i nverted fl are.
(11) Remove the fl ari ng tool s and veri fy that the
i nverted fl are i s correct.
STOP LAMP SWITCH
REMOVAL
(1) Remove steeri ng col umn cover and l ower tri m
panel for swi tch access (i f necessary).
(2) Press brake pedal downward to ful l y appl i ed
posi ti on.
(3) Rotate swi tch approxi matel y 30 i n counter-
cl ockwi se di recti on to unl ock swi tch retai ner. Then
pul l swi tch rearward and out of bracket.
(4) Di sconnect swi tch wi re harness and remove
swi tch from vehi cl e (Fi g. 19).
INSTALLATION
(1) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(2) Connect harness wi res to swi tch.
(3) Press and hol d brake pedal i n appl i ed posi ti on.
(4) I nstal l swi tch as fol l ows: Al i gn tab on swi tch
wi th notch i n swi tch bracket. Then i nsert swi tch i n
bracket and turn i t cl ockwi se about 30 to l ock i t i n
pl ace.
(5) Rel ease brake pedal . Then pul l pedal ful l y rear-
ward. Pedal wi l l set pl unger to correct posi ti on as
pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make racheti ng sound as i t sel f adjusts.
BRAKE PEDAL
REMOVAL
(1) Remove l ower tri m panel and ai r condi ti oni ng
duct i f necessary.
(2) Remove steeri ng col umn l ower tri m panel and
bezel .
(3) Remove necessary dash panel -to-i nstrument
panel brace rods.
(4) Remove retai ner cl i p and washers attachi ng
booster push rod to pedal pi n (Fi g. 20).
(5) Remove nut securi ng pedal shaft i n support
bracket.
(6) Sl i de pedal shaft outward for cl earance and
remove brake pedal .
(7) Remove pedal bushi ngs i f they are to be
repl aced.
INSTALLATION
(1) I nstal l new bushi ngs i n pedal . Lubri cate bush-
i ngs and pi vot pi n wi th Mopar mul ti -mi l eage grease.
(2) Posi ti on pedal , sl eeve and spacer(s) i n bracket
and i nstal l pedal shaft i n support and through pedal .
(3) I nstal l new nut on pedal shaft. Shaft nut is
specially formed and should not be reused. Be
sure to install new nut to secure shaft.
(4) Ti ghten pedal shaft nut to 27 Nm (20 ft. l bs.)
on model s wi th manual transmi ssi on. Ti ghten nut to
35 Nm (26 ft. l bs.) on model s wi th automati c trans-
mi ssi on.
(5) I nstal l bushi ng on pedal pi n i f removed (Fi g.
20).
(6) I nstal l booster push rod on pedal pi n. Secure
push rod to pedal wi th retai ner ri ng and washers.
(7) I nstal l dash brace rod, i f equi pped.
(8) I nstal l i nstrument panel tri m and ai r condi -
ti oni ng duct i f removed.
Fig. 18 Inverted Flare Tools
Fig. 19 Stop Lamp Switch
RETAINER TERMINALS SWITCH PLUNGER
5 - 14 BRAKES ZG
(9) Check and adjust brakel amp swi tch i f neces-
sary.
COMBINATION VALVE
REMOVAL
(1) Remove brake l i nes that connect master cyl i n-
der to combi nati on val ve (Fi g. 21).
(2) Di sconnect brake l i nes that connect combi na-
ti on val ve to HCU.
(3) Di sconnect wi re from combi nati on val ve swi tch
termi nal . Be careful when separati ng wi re connector
as l ock tabs are easi l y damaged i f not ful l y di sen-
gaged.
(4) Remove nuts attachi ng combi nati on val ve
bracket to booster studs and val ve bracket off booster
studs (Fi g. 22).
INSTALLATION
(1) Posi ti on val ve bracket on booster studs and
ti ghten bracket attachi ng nuts to 18 Nm (155 i n.
l bs.).
(2) Al i gn and start al l four brake l i ne fi tti ngs i n
combi nati on val ve by hand to avoi d cross threadi ng.
Then ti ghten fi tti ngs just enough to prevent l eakage.
(3) Connect wi re to di fferenti al pressure swi tch i n
combi nati on val ve.
(4) Ti ghten brake l i ne fi tti ngs at master cyl i nder
just enough to prevent l eakage.
(5) Attach HCU sol enoi d harness connectors to
combi nati on val ve bracket.
(6) Bl eed brakes.
MASTER CYLINDER
REMOVAL
(1) Remove brake l i nes from master cyl i nder.
(2) Remove combi nati on val ve.
(3) Remove nuts that attach master cyl i nder to
booster studs (Fi g. 23). Retain nuts as they are
special locking types.
(4) Remove master cyl i nder from booster.
Fig. 20 Brake Pedal Mounting
DASH PANELBOOSTER PUSH ROD FWD MASTER CYLIN- DER/BRAKE BOOSTER ASSEMBLY PUSH ROD RETAINER CLIP FLOORPAN BOOSTER LOCK NUTS 39 Nm (29 ft. lbs) BUSHING (FOR PIN) PUSH ROD PIN BRAKE PEDAL AND BRACKET ASSEM- BLY
Fig. 21 Combination Valve Brake Lines
Fig. 22 Combination Valve Bracket
BOOSTER STUD VALVE BRACKET COMBINA- TION VALVE
Fig. 23 Master Cylinder Mounting
CYLINDER ATTACHING NUTS (2) VALVE BRACKET
ZG BRAKES 5 - 15
INSTALLATION
(1) Remove protecti ve cover from end of pri mary
pi ston.
(2) Bl eed master cyl i nder.
(3) Sl i de master cyl i nder onto booster studs. Al i gn
booster push rod i n cyl i nder pri mary pi ston and seat
cyl i nder agai nst booster.
(4) I nstal l master cyl i nder mounti ng nuts and
ti ghten nuts to 18 Nm (155 i n. l bs.). Use original
or factory replacement nuts only.
(5) I nstal l combi nati on val ve and ti ghten mounti ng
nuts to 18 Nm (155 i n. l bs.).
(6) I nstal l brake l i nes that connect master cyl i nder
to combi nati on val ve.
(7) Fi l l and bl eed brake system.
POWER BRAKE BOOSTER
REMOVAL
(1) Remove ai r fi l ter housi ng.
(2) Remove master cyl i nder, combi nati on val ve,
and HCU.
(3) Di sconnect vacuum hose at booster check val ve
(Fi g. 24).
(4) Remove retai ner cl i p that hol ds booster push
rod on pedal pi n (Fi g. 25). Then sl i de push rod off
pi n.
(5) Remove four l ocknuts that attach booster to
dash panel .
(6) I n engi ne compartment, sl i de booster forward,
ti l t i t upward sl i ghtl y, and remove i t from engi ne
compartment.
(7) I f booster wi l l be stored on bench for any
l ength of ti me, cover booster wi th shop towel s to pre-
vent dust entry and pl ace short l engths of rubber
hose over booster studs to protect threads.
INSTALLATION
(1) Check condi ti on of grommet that secures check
val ve i n booster. Repl ace grommet i f cut, torn, or
l oose (no l onger secures val ve ti ghtl y).
(2) Wi pe booster mounti ng surface of dash panel
cl ean wi th shop towel .
(3) Al i gn and posi ti on booster on engi ne compart-
ment si de of dash panel .
(4) I nsi de passenger compartment:
(a) Lubri cate pedal pi n and bushi ng wi th Mopar
mul ti -mi l eage grease.
(b) I nstal l booster attachi ng nuts on studs.
Ti ghten attachi ng nuts to 39 Nm (29 ft. l bs.).
(c) Sl i de booster push rod on pedal pi n. Then
secure rod to pi n wi th retai ner cl i p.
(5) I n engi ne compartment, attach vacuum hose to
booster check val ve.
(6) I nstal l master cyl i nder, combi nati on val ve, and
HCU. Refer to procedures i n thi s secti on.
(7) Bl eed brakes. Refer to secti on coveri ng brake
bl eedi ng.
(8) I nstal l engi ne ai r cl eaner and hoses.
DISC BRAKE CALIPER
REMOVAL
(1) Rai se vehi cl e and remove front wheel and ti re
assembl i es.
(2) Remove and di scard brake hose mounti ng bol t
(Fi g. 26).
(3) Remove cal i per mounti ng bol ts.
Fig. 24 Booster Check Valve And Hose
VACUUM HOSE CHECK VALVE BOOSTERSTUDS
Fig. 25 Power Brake Booster Mounting
BRAKE PEDAL AND BRACKET ASSEMBLY DASH PANEL BOOSTER PUSHROD FWD MASTER CYLINDER/BRAKE BOOSTER ASSEMBLY PUSH ROD RETAINER CLIP FLOORPAN BOOSTER LOCK NUTS 39 Nm (29 ft. lbs.) PUSH ROD PIN BUSHING (FOR PIN)
5 - 16 BRAKES ZG
(4) Rotate cal i per rearward wi th pry tool i f neces-
sary. Then rotate cal i per and brake shoes off mount-
i ng l edges.
(5) Remove cal i per from vehi cl e.
INSTALLATION
(1) I nstal l brake shoes i n cal i per.
(2) Connect brake hose to cal i per but do not
ti ghten fi tti ng bol t compl etel y at thi s ti me. Be sure
to use new gaskets on bolt to avoid leaks
(3) I nstal l cal i per. Posi ti on mounti ng notches at
l ower end of brake shoes on bottom mounti ng l edge.
Then rotate cal i per over rotor and seat notches at
upper end of shoes on mounti ng l edge.
(4) Coat cal i per mounti ng bol ts wi th si l i cone
grease. Then i nstal l and ti ghten bol ts to 10-20 Nm
(7-15 ft. l bs.).
CAUTION: If new caliper bolts are being installed,
or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. If the bolts have a shank length greater than
67.6 mm (2.66 in.), they may contact the inboard
brake shoe causing a partial apply condition. Refer
to Figure 14 for the required caliper bolt length.
(5) Posi ti on front brake hose cl ear of al l chassi s
components and ti ghten cal i per fi tti ng bol t to 31 Nm
(23 ft. l bs.).
CAUTION: Be sure the brake hose is not twisted or
kinked at any point. Also be sure the hose is clear
of all steering and suspension components. Loosen
and reposition the hose if necessary.
(6) I nstal l wheel and ti re assembl y.
(7) Fi l l master cyl i nder and bl eed brake system.
DISC BRAKE SHOES
REMOVAL
(1) Rai se vehi cl e and remove front wheel and ti re
assembl i es.
(2) Drai n smal l amount of fl ui d from master cyl i n-
der front brake reservoi r wi th sucti on gun.
(3) Bottom cal i per pi ston i n bore wi th C-cl amp.
Posi ti on cl amp screw on outboard brake shoe and
cl amp frame on rear of cal i per. Typi cal C-cl amp
attachment i s shown i n (Fi g. 27). Do not allow
clamp screw to bear directly on outboard shoe
retainer spring. Use wood or metal spacer
between shoe and clamp screw if necessary.
(4) Remove cal i per mounti ng bol ts (Fi g. 28).
(5) Ti l t top of cal i per outward wi th pry tool i f nec-
essary (Fi g. 29) and remove cal i per.
Fig. 26 Brake Hose And Bolt
FITTING WASHERS CALIPERS
Fig. 27 Bottoming Caliper Piston With C-Clamp
CALIPER BOSS OUTBOARD BRAKESHOE C-CLAMP
Fig. 28 Caliper Mounting Bolts
CALIPER MOUNTER BOLT (2) CALIPER
ZG BRAKES 5 - 17
(6) Remove outboard shoe by pressi ng one end of
shoe i nward to di sengage shoe l ug. Then rotate shoe
upward unti l retai ner spri ng cl ears cal i per. Press
opposi te end of shoe i nward to di sengage shoe l ug
and rotate shoe up and out of cal i per (Fi g. 30).
(7) Remove i nboard shoe. Grasp ends of shoe and
ti l t shoe outward to rel ease spri ngs from cal i per pi s-
ton (Fi g. 31). Then remove shoe from cal i per.
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not inter-
changeable.
(8) Secure cal i per to nearby suspensi on part wi th
wi re. Do not allow brake hose to support caliper
weight.
(9) Wi pe cal i per off wi th shop rags or towel s. Do
not use compressed air. Compressed air can
unseat dust boot and force dirt into piston
bore.
INSTALLATION
(1) Cl ean brake shoe mounti ng l edge sl i de surfaces
of steeri ng knuckl e wi th wi re brush. Then appl y l i ght
coat of Mopar mul ti -mi l eage grease to sl i de surfaces.
Lubri cate mounti ng bol ts and bushi ngs wi th si l i cone
grease (Fi g. 32).
(2) I nstal l i nboard shoe i n cal i per and veri fy shoe
retai ni ng spri ngs are ful l y seated i nto the pi ston.
(3) I nstal l outboard shoe i n cal i per by starti ng one
end of shoe i n cal i per and rotati ng shoe downward
i nto pl ace. Veri fy shoe l ocati ng l ugs and shoe spri ng
are seated.
(4) I nstal l cal i per by posi ti on notches at l ower end
of brake shoes on bottom mounti ng l edge. Then
i nstal l cal i per over rotor and seat upper ends of
brake shoes on top mounti ng l edge (Fi g. 33).
CAUTION: Before securing the caliper, be sure the
caliper brake hose is not twisted, kinked or touch-
ing any chassis components.
Fig. 29 Caliper Removal
TILT CALIPER OUTBOARD TO REMOVE
Fig. 30 Outboard Brake Shoe Removal
OUTBOARD BRAKESHOE SHOE SPRING LOCATING LUG CALIPER LOCATING LUG
Fig. 31 Inboard Brake Shoe Removal
CALIPER PISTON SHOE SPRINGS INBOARD BRAKE- SHOE
Fig. 32 Caliper Lubrication Points
BUSHINGSCALIPER MOUNTING BOLTS MOUNTING LEDGES
5 - 18 BRAKES ZG
(5) I nstal l and ti ghten cal i per mounti ng bol ts to
10-20 Nm (7-15 ft. l bs.).
CAUTION: If new caliper bolts are being installed,
or if reason for repair was a drag/pull condition,
check caliper bolt length. If the bolts have a shank
length greater than 67.6 mm (2.66 in.), they will con-
tact the inboard brake shoe causing a partial apply
condition. Refer to (Fig. 34) for correct caliper bolt
length.
(7) Pump brake pedal unti l cal i per pi stons and
brake shoes are seated.
(8) Top off brake fl ui d l evel i f necessary.
DISC BRAKE ROTOR
REMOVAL
(1) Remove wheel and ti re assembl e.
(2) Remove cal i per.
(3) Remove retai ners securi ng rotor to hub studs
(Fi g. 35).
(4) Remove rotor from hub.
(5) I f rotor shi el d requi res servi ce, remove front
hub and beari ng assembl y.
INSTALLATION
(1) I f new rotor i s bei ng i nstal l ed, remove protec-
ti ve coati ng from rotor surfaces wi th carburetor
cl eaner.
(2) I nstal l rotor on hub.
(3) I nstal l cal i per.
(4) I nstal l new spri ng nuts on wheel studs.
REAR DISC BRAKE CALIPER
REMOVAL
(1) Rai se vehi cl e and remove ti re and wheel
assembl i es.
(2) Press cal i per pi ston i nto cal i per bore wi th
C-cl amp (Fi g. 36).
(3) Remove cal i per mounti ng bol ts (Fi g. 37).
(4) Rotate cal i per rearward by hand or wi th pry
tool . Then rotate cal i per and brake shoes off l edges of
mounti ng bracket.
(5) Remove cal i per fi tti ng bol t and di sconnect rear
brake hose at cal i per. Di scard metal washers on fi t-
ti ng bol t. Washers shoul d be repl aced and not reused.
(6) Remove cal i per from vehi cl e.
INSTALLATION
(1) Veri fy that brake shoes are correctl y posi ti oned
i n cal i per.
Fig. 33 Caliper Installation
TOP LEDGE BRAKESHOE TAB ON LEDGE OUTER SURFACE LEDGE SEATED IN BRAKESHOE NOTCH BOTTOMLEDGE
Fig. 34 Mounting Bolt Dimensions
CORRECT SHANK LENGTH: 67 mm ( 0.6 mm) 2.637 in. ( 0.0236 in.) 22 mm (0.866 in.) THREADLENGTH CALIPER BOLT
Fig. 35 Rotor & Hub
ROTOR RETAINER BEARING NUT NUT LOCK COTTER PIN WASHER
ZG BRAKES 5 - 19
(2) Posi ti on cal i per over rotor and i nto bracket. Be
sure brake shoe tabs are properl y seated on mount-
i ng bracket l edges.
(3) Connect rear brake hose to cal i per. Use new
washers on hose fi tti ng and ti ghten hose fi tti ng bol t
to 24-38 Nm (216-336 i n. l bs.).
(4) Check brake hose posi ti on before proceedi ng.
Veri fy that hose i s not twi sted, ki nked, or touchi ng
any suspensi on components.
CAUTION: Check caliper bolt length before pro-
ceeding (Fig. 38). If the bolts have a shank length
greater than 67.6 mm (2.66 in.), they will contact the
inboard brake shoe causing a partial apply condi-
tion.
(5) Lubri cate and i nstal l cal i per mounti ng bol ts.
Start bol ts by hand then ti ghten bol ts to 10-20 Nm
(7-15 ft. l bs.).
(6) Fi l l and bl eed brake system.
REAR DISC BRAKE SHOES
REMOVAL
(2) Remove rear wheel and ti re assembl i es.
(3) Press cal i per pi ston back i nto cal i per bore wi th
l arge Cackl i ng.
(4) Remove cal i per mounti ng bol ts.
(5) Rotate cal i per rearward and off rotor (Fi g. 39).
Support cal i per wi th wi re attached to nearby suspen-
si on component. Do not allow brake hose to sup-
port caliper weight.
(6) Press one corner of outboard shoe i nward then
pry shoe upward wi th sui tabl e tool and rotate shoe
out of cal i per.
(7) Pry i nboard shoe outward unti l shoe retai ners
come out of cal i per pi ston. Then remove shoe from
cal i per.
(8) I nspect cal i per mounti ng bol t bushi ngs and
boots. Repl ace boots i f torn or cut. Repl ace bushi ngs,
or bol ts i f ei ther exhi bi ts wear, or heavy corrosi on.
Fig. 36 Bottoming Caliper Piston
CALIPER OUTBOARD SHOE LARGE C-CLAMP
Fig. 37 Caliper Mounting Bolt
MOUNTINGBOLT 13 mm SOCKET CALIPER
Fig. 38 Caliper Mounting Bolt Dimensions
CORRECT SHANK LENGTH: 67 mm ( 0.6 mm) 2.637 in. ( 0.0236 in.) 22 mm (0.866 in.) THREADLENGTH CALIPER BOLT
Fig. 39 Rear Caliper
BOOT/BUSHING (2) INBOARD SHOE OUTBOARD SHOE
5 - 20 BRAKES ZG
INSTALLATION
(1) Cl ean brake shoe contact surfaces of cal i per
mounti ng bracket (Fi g. 40). Use wi re brush or emery
cl oth.
(3) I nstal l cal i per over rotor and i nto mounti ng
bracket.
(4) Veri fy that brake shoe l ugs are properl y seated
on cal i per mounti ng bracket (Fi g. 41). Be sure
spri ngs on outboard shoes are al so seated agai nst
bracket.
(5) Veri fy hose must not be twi sted or ki nked.
(6) Lubri cate and i nstal l cal i per mounti ng bol ts
and ti ghten to 10-20 Nm (7-15 ft. l bs.).
(8) Turn i gni ti on On and run HCU pump unti l i t
shuts off. Then pump brake pedal unti l shoes are
seated and i ndi cator l i ghts go out.
(9) Top off brake fl ui d l evel i f necessary. Use
Mopar brake fl ui d or equi val ent meeti ng SAD Djawa
and DOT 3 standards onl y.
REAR DISC BRAKE ROTOR
REMOVAL
(1) Rai se vehi cl e.
(3) Remove cal i per.
(4) Remove access pl ug from spl ash shi el d and
back off parki ng brake shoes by rotati ng adjuster
screw star wheel wi th brake tool (Fi g. 42). At dri ver
si de rear wheel , rotate adjuster screw star wheel
cl ockwi se to back off shoes. At passenger si de wheel ,
rotate star wheel i n countercl ockwi se di recti on.
Di recti on of rotati on i s whi l e l ooki ng from rear to
front of vehi cl e.
(5) I f rotor and/or axl e hub contact surfaces are
heavi l y rusted, appl y rust penetrant oi l to rotor and
axl e hub and through spaces around wheel studs.
(6) Remove push nuts securi ng rotor to axl e shaft
studs.
(7) Work rotor off axl e hub and studs. Use pl asti c
or rawhi de mal l et to l oosen rotor i f necessary.
(8) Cl ean and i nspect rotor braki ng surfaces.
Refi ni sh, or repl ace rotor i f necessary.
INSTALLATION
(1) Cl ean axl e hub and hub bore i n rotor wi th wi re
brush, or emery cl oth.
(2) I nstal l rotor on axl e hub.
(3) I nstal l di sc brake cal i per.
(4) I nstal l wheel and ti re assembl y and l ower vehi -
cl e.
(5) Adjust parki ng brake shoes. Use brake tool to
rotate adjuster screw star wheel . Ti ghten shoes unti l
l i ght drag i s created. Then back off shoes about 1/2 to
one turn of star wheel .
(6) I nstal l pl ug i n spl ash shi el d access hol e.
(7) Pump brake pedal to seat cal i per pi ston and
brake shoes. Do not move vehi cl e unti l fi rm brake
pedal i s obtai ned.
Fig. 40 Brake Shoe Contact Surfaces
MOUNTING BRACKET CON- TACT SURFACES
Fig. 41 Correct Brake Shoe Position
SHOE TABS SHOE TABS ANTI-RATTLE SPRING CALIPER BRACKET
Fig. 42 Backing Off Parking Brake Shoes
SPLASH SHIELD ACCESS HOLE BRAKE ADJUSTING TOOL
ZG BRAKES 5 - 21
PARKING BRAKE HAND LEVER
REMOVAL
(1) Rel ease parki ng brakes.
(2) Di sconnect battery negati ve cabl e.
(4) Remove front cabl e adjusti ng nut and di sen-
gage cabl e tensi oner from equal i zer. Then remove
front cabl e from tensi oner (Fi g. 43).
(5) Di sengage front cabl e from i nsert and i nsert
from fl oorpan.
(7) Remove center consol e, refer to Group 23 Body.
(8) Di sconnect parki ng brake swi tch and ai r bag
modul e wi ri ng connectors.
(9) Remove screws attachi ng ai r bag control mod-
ul e to fl oorpan and parki ng brake l ever. Then move
modul e asi de for access to l ever (Fi g. 44).
(10) Remove screws attachi ng parki ng brake l ever
to bracket and l i ft l ever upward for access to front
cabl e.
(11) Di sengage front cabl e from parki ng brake
l ever and remove l ever assembl y from vehi cl e.
INSTALLATION
(1) Connect front cabl e to l ever assembl y.
(2) Seat front cabl e i n fl oor pan.
(3) I nstal l l ever assembl y on mounti ng bracket.
(4) Connect parki ng brake swi tch wi re.
(5) I nstal l ai r bag control modul e and connect
modul e wi res harnesses.
(6) I nstal l parki ng l ever cover.
(7) I nstal l center consol e, refer to Group 23 Body.
(9) Assembl e front cabl e, cabl e tensi oner and cabl e
bracket.
(10) Adjust parki ng brake front cabl e.
(12) Connect battery negati ve cabl e.
FRONT PARKING BRAKE CABLE
REMOVAL
(1) Rel ease parki ng brakes.
(2) Di sconnect battery negati ve cabl e and rai se
vehi cl e on hoi st.
(3) Remove front cabl e adjusti ng nut and di sen-
gage cabl e tensi oner from equal i zer. Then remove
front cabl e from tensi oner (Fi g. 45).
(4) Di sengage front cabl e from i nsert and i nsert
from fl oorpan.
(6) Remove consol e, refer to Group 23 Body.
(7) Remove park brake l ever.
(8) Di sconnect front cabl e from parki ng brake
l ever and remove cabl e.
Fig. 43 Park Brake Cable Attachment
FRONT CABLE FWD CABLE SUPPORT BRACKET L.R. CABLE R.R.CABLE FRONT CABLE TEN- SIONER ADJUSTING NUT EQUALIZER
Fig. 44 Air Bag Module Mounting
AIR BAG MODULE PARKING BRAKE LEVER ASSEM- BLY FLOOR PAN FWD MODULE DIAGNOSTIC CONNEC- TOR MODULE WIRE HARNESS
Fig. 45 Park Brake Cable Attachment
FRONT CABLE FWD CABLE SUPPORT BRACKET L.R. CABLE R.R.CABLE FRONT CABLE TEN- SIONER ADJUSTING NUT EQUALIZER
5 - 22 BRAKES ZG
INSTALLATION
(1) Connect front cabl e to l ever assembl y.
(2) Seat front cabl e i n fl oor pan.
(3) I nstal l l ever assembl y.
(4) I nstal l consol e.
(6) Assembl e front cabl e, cabl e tensi oner and
equal i zer.
(7) Adjust parki ng brake system i f new cabl e, or
tensi oner has been i nstal l ed, or i f tensi oner mecha-
ni sm has been l oosened, or removed for access to
other components. Refer to Parki ng Brake Adjust-
ment procedure i n thi s secti on.
REAR PARKING BRAKE CABLE
REMOVAL
(1) Rai se vehi cl e and l oosen adjusti ng nut at
equal i zer to provi de sl ack i n rear cabl es.
(2) Di sengage cabl e at equal i zer. Then di sengage
cabl e from body and chassi s cl i ps and retai ners.
(3) Sl i de cabl e eyel et off actuati ng l ever (Fi g. 46).
(4) Compress retai ner securi ng cabl e i n bracket
attached to cal i per bracket. Then remove cabl e from
bracket.
INSTALLATION
(1) I nstal l cabl e eyel et on l ever. Be sure eyel et i s
seated i n l ever notch.
(2) Seat cabl e retai ner i n cal i per bracket.
(3) Route cabl e up to cabl e tensi oner and equal i zer.
Then connect cabl e to equal i zer.
(4) Check cabl e routi ng. Be sure cabl e i s secured
i n body and chassi s cl i ps and retai ners. Al so be sure
cabl e i s not twi sted, ki nked or touchi ng any rotati ng
components.
(5) Adjust parki ng brake.
PARKING BRAKE SHOES
REMOVAL
(2) Remove rear wheel and ti re assembl y.
(3) Remove cal i per. Do not allow brake hose to
support caliper weight. Support caliper with
wire attached to suspension component.
(4) Remove rubber access pl ug from back of rear
di sc brake spl ash shi el d.
(5) Retract parki ng brake shoes wi th brake
adjuster tool (Fi g. 47). Posi ti on tool at top of star
wheel and rotate wheel downward i n cl ockwi se di rec-
ti on (whi l e faci ng front of vehi cl e).
(6) Remove rotor from axl e hub fl ange.
(7) Remove shoe hol d-down cl i ps and pi ns (Fi g.
48). Cl i p i s hel d i n pl ace by pi n whi ch fi ts i n cl i p
notch. To remove cl i p, fi rst push cl i p ends together
wi th thumb or forefi nger. Next, sl i de cl i p upward
unti l head of pi n cl ears narrow part of notch. Then
remove pi n and cl i p.
(8) Remove upper and l ower spri ngs from shoes
wi th needl e nose pl i ers (Fi g. 49).
(9) Ti l t shoes outward and remove adjuster screw.
Note adjuster screw position for installation
reference.
(10) I nspect condi ti on of al l brake components.
Repl ace parts i f bent, damaged or worn.
(11) Cl ean and i nspect condi ti on of adjuster screw
assembl y. Repl ace assembl y i f worn, or damaged.
INSTALLATION
(1) Lubri cate shoe contact pads and cam and l ever
wi th Mopar mul ti -mi l eage grease (Fi g. 50).
(2) I nstal l shoes on spl ash shi el d wi th hol d down
cl i ps and pi ns. Be sure shoes are properl y engaged i n
cal i per bracket and cam.
(3) I nstal l adjuster screw assembl y. Be sure
notched ends of screw assembl y are properl y seated
Fig. 46 Rear Cable Attachment
CABLE BRACKET LEVER CABLE EYE- LET
Fig. 47 Retracting Parking Brake Shoes
ZG BRAKES 5 - 23
on shoes and that star wheel i s al i gned wi th access
hol e i n shi el d.
(4) I nstal l shoe upper and l ower return spri ng.
Needl e nose pl i ers can be used to connect spri ng to
each shoe. Operate l ever to veri fy that shoes expand
and retract properl y.
(5) I nstal l rotor and cal i per.
(6) Adjust parki ng brake shoes.
(8) Adjust parki ng brake cabl e tensi oner.
(9) Lower vehi cl e and veri fy correct parki ng brake
operati on.
PARKING BRAKE CAM AND LEVER
NOTE: The cams are reversible and can be used on
either wheel. The levers are NOT reversible. They
are marked R and L and the lever notch (for the
cable eyelet), must faces rearward on both sides.
REMOVAL
(3) Remove brake cal i per and rotor.
(4) Remove parki ng brake shoes.
(5) Move l ever forward and di sconnect parki ng
brake rear cabl e from l ever.
(6) Pul l l ever forward through boot. Di sengage
cam from l ever and remove cam (Fi g. 51). Note cam
posi ti on for i nstal l ati on reference.
(7) Remove l ever.
INSTALLATION
(1) Lubri cate repl acement l ever wi th si l i cone
grease. Then i nsert l ever part way through boot. Be
sure l ever notch i s faci ng rearward.
Fig. 48 Hold-Down Clip And Pin
AXLE SHAFT FLANGE REAR SHOE HOLDDOWN CLIP AND PIN REAR SHOE HOLDDOWN CLIP AND PIN
Fig. 49 Lower Spring
ADJUSTER SCREW LOWER SPRING REAR SHOE NEEDLENOSE PLIERS
Fig. 50 Shoe Contact Pads
SPLASH SHIELD
SHOE CON-
TACT PADS
Fig. 51 Cam, Lever And Boot
LEVER BOOT LEVER CAM
5 - 24 BRAKES ZG
(2) Engage cam i n l ever. Then si mul taneousl y sl i de
cam i nto pl ace on spl ash shi el d and work l ever
through boot (Fi g. 52).
(3) I nstal l parki ng brake shoes.
(4) Veri fy correct i nstal l ati on of cam and l ever by
pul l i ng l ever toward front of vehi cl e. Cam shoul d
expand both brake shoes as l ever i s pul l ed forward.
(5) I nstal l rotor and adjust parki ng brake shoes.
(6) Connect rear cabl e to l ever. Be sure cabl e eye-
l et i s securel y attached i n l ever notch.
(7) I nstal l brake cal i per and wheel and ti re assem-
bl y.
(8) Lower vehi cl e and veri fy correct parki ng brake
operati on.
SPLASH SHIELD/CALIPER BRACKET/LEVER BOOT
REMOVAL
(1) Rai se vehi cl e and remove wheel and ti re
assembl y.
(2) Remove cal i per bol ts and l i ft cal i per off rotor
and bracket. Suspend cal i per from chassi s or suspen-
si on component wi th wi re.
(3) Retract parki ng brake shoes and remove rotor.
(4) Remove axl e shaft. Refer to Group 3 for proce-
dure.
(5) Remove parki ng brake shoes from spl ash
shi el d.
(6) Remove nuts attachi ng spl ash shi el d and cal i -
per bracket to axl e tube fl ange.
(7) Remove spl ash shi el d and cal i per bracket from
axl e studs and work l ever out of rear cabl e eyel et.
(8) Mark posi ti on of spl ash shi el d and bracket for
assembl y reference. Use pai nt or scri be to mark
parts.
(9) Dri l l out ri vets that retai n spl ash shi el d to cal -
i per bracket (Fi g. 53). I f ri vet heads di d not come
compl etel y off after dri l l i ng, remove remai ni ng pi eces
wi th smal l chi sel . Note that the rivets do not
have to be replaced at installation. The rivets
are only used during manufacture to keep the
boot in place during handling.
(10) Note posi ti on of cam and l ever for i nstal l ati on
reference. Then remove cam and l ever from spl ash
shi el d and bracket.
(11) Separate spl ash shi el d and cal i per bracket.
Then remove l ever boot from bracket (Fi g. 54).
INSTALLATION
(1) I f ori gi nal bracket and shi el d wi l l be reused,
cl ean them wi th Mopar carb and brake cl eaner. Al so
cl ean shoe contact pad surfaces of shi el d wi th 400
gri t paper. Lubri cate pad surfaces wi th l i ght coat of
Mopar mul ti -mi l eage grease.
Fig. 52 Cam And Lever
LEVER CAM
Fig. 53 Drilling Out Splash Shield Rivets
SPLASH SHIELD POP RIVETS BRACKET
Fig. 54 Caliper Bracket, Splash Shield And Lever
Boot
CALIPER MOUNTING BRACKET LEVER BOOT SPLASH SHIELD
ZG BRAKES 5 - 25
(2) Appl y thi n coat of contact cement or si l i cone
adhesi ve to new l ever boot and to boot mounti ng area
of cal i per bracket (Fi g. 55). Appl y adhesi ve to areas
where boot and bracket contact one another. Adhe-
si ve i s needed to hol d boot i n posi ti on when spl ash
shi el d i s attached to bracket.
(3) I nstal l new boot on cal i per bracket. Metal
retai ner part of boot fi ts over l edge on cal i per as
shown (Fi g. 56). Rubber part of boot extends through
rear openi ng i n bracket. Al l ow adhesi ve on boot and
bracket to set up for a mi nute or two before proceed-
i ng.
CAUTION: If the boot is not installed properly, it
will prevent the shield from seating squarely on the
bracket. This will cock the shield causing it to rub
against the rotor after installation.
(4) Posi ti on spl ash shi el d on cal i per bracket. Then
careful l y i nstal l shi el d and bracket assembl y on axl e
tube fl ange studs.
(5) Appl y Mopar Lock N Seal (or Locti te 242), to
axl e tube stud nuts. Then i nstal l and ti ghten nuts to
43-61 Nm (32-45 ft. l bs.).
(6) Assembl e and i nstal l cam and l ever. Push l ever
through boot and seat cam between l i p on shi el d and
l edge on bracket (Fi g. 57). Then engage l ever i n cabl e
eyel et. Be sure cabl e notch i n l ever i s faci ng rear-
ward. Remove and reposi ti on cam and l ever i f neces-
sary.
(7) I nstal l parki ng brake shoes on spl ash shi el d.
Veri fy posi ti oni ng of cam and l ever, shoes, spri ngs
and hol d-down cl i ps and pi ns (Fi g. 58).
(8) Veri fy correct posi ti oni ng of cal i per bracket and
shi el d (Fi g. 59). Cal i per openi ng and l edges shoul d be
to rear as shown.
(9) I nstal l axl e shaft, shaft retai ner cl i ps and hous-
i ng cover. Check l ube l evel and add l ubri cant i f
needed.
(10) I nstal l rotor, cal i per, and wheel and ti re
assembl y. Then adjust parki ng brake shoes.
Fig. 55 Applying Adhesive To Parking Brake Lever
Boot
BOOT ADHESIVE/SEALER OR CON- TACT CEMENT
Fig. 56 Lever Boot Installation
BRACKET LEDGE LEVER BOOT
Fig. 57 Cam And Lever Installation
LEVER CAM
Fig. 58 Parking Brake Shoes Mounted On Shield
CAM AND LEVER UPPER SPRING FRONT SHOE SPLASH SHIELD HOLDDOWN CLIPS AND PINS RIVET ADJUSTER SCREW LOWER SPRING REAR SHOE RIVET
5 - 26 BRAKES ZG
(11) Lower vehi cl e and veri fy correct servi ce and
parki ng brake operati on.
MASTER CYLINDER RESERVOIR
REMOVAL
(1) Remove reservoi r cap and empty fl ui d i nto
drai n contai ner.
(2) Remove pi ns that retai n reservoi r to master
cyl i nder. Use hammer and pi n punch to remove pi ns
(Fi g. 60).
(3) Cl amp cyl i nder body i n vi se wi th brass protec-
ti ve jaws.
(4) Loosen reservoi r from grommets wi th pry tool
(Fi g. 61).
(5) Remove reservoi r by rocki ng i t to one si de and
pul l i ng free of grommets (Fi g. 62).
(6) Remove ol d grommets from cyl i nder body (Fi g.
63).
Fig. 59 Checking Caliper Bracket And Shield
Position
BRAKESHOE LEDGE (12 OCLOCK POSITION) SPLASH SHIELD CALIPER LEDGES (TO REAR)
Fig. 60 Reservoir Retaining Pins
PIN PUNCH RESERVOIR BODY ROLL PINS
Fig. 61 Loosening Reservoir
PRY TOOL RESERVOIR GROMMET MASTER CYLINDER BODY
Fig. 62 Reservoir Removal
RESERVOIR GROMMETS
Fig. 63 Grommet Removal
MASTER CYLINDER BODY GROMMETS
ZG BRAKES 5 - 27
INSTALLATION
CAUTION: Do not use any type of tool to install
the grommets. Tools may cut, or tear the grommets
creating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubri cate new grommets wi th cl ean brake fl ui d
and I nstal l new grommets i n cyl i nder body (Fi g. 64).
Use fi nger pressure to i nstal l and seat grommets.
(2) Start reservoi r i n grommets. Then rock reser-
voi r back and forth whi l e pressi ng downward to seat
i t i n grommets.
(3) I nstal l pi ns that retai n reservoi r to cyl i nder
body.
(4) Fi l l and bl eed master cyl i nder on bench before
i nstal l ati on i n vehi cl e.
DISC BRAKE CALIPER
DISASSEMBLY
(1) Remove brake shoes from cal i per.
(2) Drai n brake fl ui d out of cal i per.
(3) Pad i nteri or of cal i per wi th mi ni mum, 2.54 cm
(1 i n.) thi ckness of shop towel s or rags (Fi g. 65). Tow-
el s are needed to protect cal i per pi ston duri ng
removal .
(4) Remove cal i per pi ston wi th short bursts of
l ow pressure compressed ai r. Di rect ai r through fl ui d
i nl et port and ease pi ston out of bore (Fi g. 66).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out. NEVER attempt to catch the
piston as it leaves the bore. This will result in per-
sonal injury.
Fig. 64 Grommet Installation
WORK NEW GROMMETS INTO PLACE USING FINGER PRES- SURE ONLY
Fig. 65 Padding Caliper Interior
SHOP TOWELS OR CLOTHS CALIPER
Fig. 66 Caliper Piston Removal
AIR GUN CALIPER PISTON PADDING MATERIAL
5 - 28 BRAKES ZG
(5) Remove cal i per pi ston dust boot wi th sui tabl e
tool (Fi g. 67) and di scard boot.
(6) Remove cal i per pi ston seal wi th wood or pl asti c
tool (Fi g. 68) and di scard seal . Do not use metal tool s
as they wi l l scratch pi ston bore.
(7) Remove cal i per mounti ng bol t bushi ngs and
boots (Fi g. 69).
ASSEMBLY
(1) Coat cal i per pi ston bore, new pi ston seal and
pi ston wi th cl ean brake fl ui d.
(2) Lubri cate cal i per bushi ngs and i nteri or of
bushi ng boots wi th Di el ectri c si l i cone grease.
(3) I nstal l bushi ng boots i n cal i per, then i nsert
bushi ng i nto boot and push bushi ng i nto pl ace (Fi g.
70).
(4) I nstal l new pi ston seal i nto seal groove wi th
fi nger (Fi g. 71).
Fig. 67 Caliper Piston Dust Boot Removal
COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER PISTON DUSTBOOT
Fig. 68 Piston Seal Removal
REMOVE SEAL WITH WOOD PEN- CIL OR SIM- ILAR TOOL
PISTON SEAL
Fig. 69 Mounting Bolt Bushing And Boot
Fig. 70 Bushings And Boots Installation
BUSHING BOOT
Fig. 71 Piston Seal Installation
SEAL GROOVE PISTON SEAL
ZG BRAKES 5 - 29
(5) I nstal l dust boot on cal i per pi ston and seat boot
i n pi ston groove (Fi g. 72).
(6) Press pi ston i nto cal i per bore by hand, use a
turn and push moti on to work pi ston i nto seal (Fi g.
73).
(7) Press cal i per pi ston to bottom of bore.
(8) Seat dust boot i n cal i per wi th I nstal l er Tool
C-4842 and Tool Handl e C-4171 (Fi g. 74).
(9) Repl ace cal i per bl eed screw i f removed.
REAR DISC BRAKE CALIPER
DISASSEMBLY
(1) Remove cal i per and brake shoes.
(2) Remove mounti ng bol t boots and bushi ngs from
cal i per (Fi g. 75).
(3) Pad i nteri or of cal i per wi th mi ni mum, one-i nch
thi ckness of shop towel s or rags (Fi g. 76). Towel s are
needed to protect cal i per pi ston duri ng removal .
(4) Remove cal i per pi ston wi th short bursts of
l ow pressure compressed ai r. Di rect ai r through fl ui d
i nl et port and ease pi ston out of bore (Fi g. 77).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out. In addition, NEVER attempt to
catch the piston as it leaves the bore. This could
result in personal injury.
(5) Remove cal i per pi ston dust boot (Fi g. 78).
(6) Remove and di scard cal i per pi ston seal wi th
penci l , or pl asti c tool (Fi g. 79). Do not use metal tool s
as they wi l l scratch pi ston bore.
Fig. 72 Dust Boot On Piston
PIS- TION DUST BOOT
Fig. 73 Caliper Piston Installation
PISTON BOOT
Fig. 74 Piston Dust Boot Installation
HANDLE C-4171 INSTALLERC-4842 DUST BOOT
Fig. 75 Mounting Bolt Bushings And Boots
BUSHINGS BOOTS
Fig. 76 Padding Caliper
PADDING MATE- RIAL (1 THICK)
5 - 30 BRAKES ZG
ASSEMBLY
(1) Lubri cate cal i per pi ston bore and new pi ston
seal wi th cl ean brake fl ui d.
(2) I nstal l new pi ston seal i n groove machi ned i n
pi ston bore. Be sure seal i s ful l y seated and i s not
twi sted. Press seal i nto pl ace wi th fi ngerti ps.
(3) Lubri cate cal i per pi ston wi th cl ean brake fl ui d
and start pi ston i nto bore and seal by hand. Use a
twi sti ng, rocki ng moti on to start pi ston i nto seal .
Keep piston level while starting it in seal other-
wise seal can be folded over.
(4) Once pi ston i s fi rml y started i n seal , press pi s-
ton about 2/3 of way i nto bore wi th C-cl amp or bench
vi se (Fi g. 80).
CAUTION: Position a protective wood block
between the piston and C-clamp or vise jaws. The
wood block will avoid chipping or cracking the pis-
ton while pressing it into place.
(5) I nstal l dust boot on pi ston. Be sure boot l i p i s
ful l y seated i n groove at top of cal i per pi ston.
(6) Seat dust boot i n cal i per ei ther by hand, or
wi th a sui tabl e si ze i nstal l er tool (Fi g. 81).
Fig. 77 Caliper Piston Removal
AIR GUN NOZZLE PADDING CALIPER PISTON
Fig. 78 Caliper Piston Dust Boot
PISTON DUST BOOT PRY TOOL
Fig. 79 Caliper Piston Seal
WOOD PENCIL CALIPER PISTON SEAL
Fig. 80 Piston Installed In Caliper
PISTON DUST BOOT GROOVE
Fig. 81 Seating Caliper Piston Dust Boot
SUITABLE SIZE INSTALLER TOOL DUST BOOT
ZG BRAKES 5 - 31
(7) Press cal i per to bottom of bore after seati ng
dust boot. Be sure to use wood bl ock to protect pi ston
and boot.
(8) I nstal l cal i per bl eed screw, i f removed.
(9) I nstal l bushi ng and boot assembl i es i n cal i per.
Be sure boots are centered i n cal i per as shown.
(10) Appl y si l i cone grease to i nteri or of bushi ng
boots. Then appl y same l ubri cant to exteri or and
i nteri or of bushi ngs.
(11) I nstal l mounti ng bol t bushi ngs i n boots (Fi g.
82). Be sure boot l i ps are seated i n grooves at ends of
bushi ngs.
(12) Center bushi ng boots i n cal i per.
(14) I nstal l cal i per.
CALIPER
CLEANING
Cl ean the cal i per components wi th cl ean brake
fl ui d or brake cl ean onl y. Do not use gasol i ne, kero-
sene, thi nner, or si mi l ar sol vents. These products
may l eave a resi due that coul d damage the pi ston
and seal .
Wi pe the cal i per and pi ston dry wi th l i nt free tow-
el s or use l ow pressure compressed ai r.
INSPECTION
The pi ston i s made from a phenol i c resi n (pl asti c
materi al ) and shoul d be smooth and cl ean.
Repl ace the pi ston i f cracked or scored. Do not
attempt to restore a scored pi ston surface by sandi ng
or pol i shi ng. The pi ston must be repl aced i f damaged.
NOTE: If the caliper piston must be replaced,
install the same type of piston in the caliper. Never
interchange phenolic resin and steel caliper pis-
tons. The pistons, seals, seal grooves, caliper bore
and piston tolerances are different for resin and
steel pistons. Do not intermix these components at
any time.
The bore can be l i ghtl y pol i shed wi th a brake hone
to remove very mi nor surface i mperfecti ons (Fi g. 83).
The cal i per shoul d be repl aced i f the bore i s severel y
corroded, rusted, scored, or i f pol i shi ng woul d
i ncrease bore di ameter more than 0.025 mm (0.001
i nch).
ADJ USTMENTS
STOP LAMP SWITCH
(1) Press and hol d brake pedal i n appl i ed posi ti on.
(2) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(3) Rel ease brake pedal . Then pul l pedal ful l y rear-
ward. Pedal wi l l set pl unger to correct posi ti on as
pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make racheti ng sound as i t sel f adjusts.
PARKING BRAKE CABLE TENSIONER
NOTE: Parking brake adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
essary, perform the following procedure for proper
parking brake operation.
ADJ USTMENT
(2) Back off tensi oner adjusti ng nut to create sl ack
i n cabl es.
(3) Remove rear wheel /ti re assembl i es and remove
brake drums.
(4) Check rear brake shoe adjustment wi th stan-
dard brake gauge. Excessive shoe-to-drum clear-
ance, or worn brake components will result in
faulty parking brake adjustment and operation.
(5) Veri fy that parki ng brake cabl es operate freel y
and are not bi ndi ng, or sei zed. Repl ace faul ty cabl es,
before proceedi ng.
Fig. 82 Bushings Installed In Boots
BUSHINGS SEATED IN BOOTS
Fig. 83 Lightly Polishing Piston Bore WithTool
SPECIAL HONE CALIPER PISTON BORE
5 - 32 BRAKES ZG
(6) Rei nstal l brake drums and wheel /ti re assem-
bl i es after brake shoe adjustment i s compl ete.
(7) Lower vehi cl e enough for access to parki ng
brake l ever. Then fully appl y parki ng brakes. Leave
brakes appl i ed unti l adjustment i s compl ete.
(8) Rai se vehi cl e and mark tensi oner rod 6.5 mm
(1/4 i n.) from tensi oner bracket (Fi g. 84).
(9) Ti ghten adjusti ng nut at equal i zer unti l mark
on tensi oner rod moves i nto al i gnment wi th tensi oner
bracket.
(10) Lower vehi cl e unti l rear wheel s are 15-20 cm
(6-8 i n.) off shop fl oor.
(11) Rel ease parki ng brake l ever and veri fy that
rear wheel s rotate freel y wi thout drag.
NOTE: Do not loosen/tighten equalizer adjusting
nut for any reason after completing adjustment.
PARKING BRAKE SHOE
(2) Secure rotor wi th two wheel nuts.
(3) Remove rubber access pl ug from back of spl ash
shi el d.
(4) I nsert brake tool through access hol e i n spl ash
shi el d (Fi g. 85). Posi ti on tool at bottom of star wheel .
(5) Rotate star wheel upward i n countercl ockwi se
di recti on to expand shoes (whi l e faci ng front of vehi -
cl e).
(6) Expand shoes unti l l i ght drag i s experi enced.
Then back off adjuster screw onl y enough to el i mi -
nate drag.
(7) I nstal l pl ug i n spl ash shi el d access hol e.
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
BRAKE COMPONENTS
Front Disc Brake Caliper
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl oati ng
Front Disc Brake Rotor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Venti l ated
Max. Runout . . . . . . . . . . . . . 0.13 mm (0.005 i n.)
Max. Thi ckness Vari ati on . . 0.013mm (0.0005 i n.)
Rear Disc Brake Caliper
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl oati ng
Rear Disc Brake Rotor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sol i d
Max. Runout . . . . . . . . . . . . . 0.13 mm (0.005 i n.)
Max. Thi ckness Vari ati on . . 0.0254 mm (0.001 i n.)
Fig. 84 Tensioner Rod Measurement
TENSIONER BRACKET 6.5 MM (1/4 in.) TENSIONER ROD ROD TO EQUALIZER
Fig. 85 Park Brake Shoe Adjustment
ZG BRAKES 5 - 33
Front Disc Brake Caliper
Brake Booster
Type . . . . . . . . . . . . . . . . . . . . . . Dual Di aphragm
TORQUE CHART
DESCRIPTION TORQUE
Brake Pedal
Support Bol t . . . . . . . . . 23-34 Nm (17-25 ft. l bs.)
Pi vot Bol t/Nut . . . . . . . . 27-35 Nm (20-26 ft. l bs.)
Brake Booster
Mounti ng Nuts . . . . . . . . . . . . 39 Nm (29 ft. l bs.)
Master Cylinder
Mounti ng Nuts . . . . . . . . . . . 18 Nm (155 i n. l bs.)
Pri mary Brake Li ne . . . . . . . 16 Nm (144 i n. l bs.)
Secondary Brake Li ne . . . . . . 16 Nm (144 i n. l bs.)
Combination Valve
Mounti ng Nuts . . . . . . . . . . . 18 Nm (155 i n. l bs.)
Pri mary/Secondary Brake
Li nes . . . . . . . . . . . . . . . . . . 21 Nm (185 i n. l bs.)
Front Caliper
Mounti ng Bol ts . . . . . . . . 10-20 Nm (7-15 ft. l bs.)
Brake Hose Bol t . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Rear Caliper
Mounti ng Bol ts . . . . . . . . 10-20 Nm (7-15 ft. l bs.)
Brake Hose Bol t . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Parking Brake
Lever Screws . . . . . . . . . . 10-14 Nm (7-10 ft. l bs.)
Lever Bracket Screws . . . 10-14 Nm (7-10 ft. l bs.)
Cabl e Retai ner Nut . . . . . 1-2 Nm (12-16 i n. l bs.)
SPECIAL TOOLS
BASE BRAKES
Installer Caliper Dust Boot C-4842
Handle C-4171
5 - 34 BRAKES ZG
ANTILOCK BRAKES
INDEX
page page
GENERAL INFORMATION
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . 35
ABS SYSTEM RELAYS . . . . . . . . . . . . . . . . . . 38
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . 38
ACCELERATION SWITCH . . . . . . . . . . . . . . . . 38
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . 35
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . 37
CONTROLLER ANTILOCK BRAKES . . . . . . . . . 36
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . 36
WHEEL SPEED SENSORS AND TONE WHEEL . .
37
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . 38
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . 38
ACCELERATION SWITCH . . . . . . . . . . . . . . . . 40
FRONT WHEEL SPEED SENSOR . . . . . . . . . . 39
HYDRAULIC CONTROL UNIT/CONTROLLER
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . 38
REAR WHEEL SPEED SENSOR . . . . . . . . . . . 40
ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . . 41
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 42
GENERAL INFORMATION
ANTILOCK BRAKE SYSTEM
The anti l ock brake system (ABS) i s an el ectroni -
cal l y operated, al l wheel brake control system.
The system i s desi gned to prevent wheel l ockup
and mai ntai n steeri ng control duri ng peri ods of hi gh
wheel sl i p when braki ng. Preventi ng l ockup i s accom-
pl i shed by modul ati ng fl ui d pressure to the wheel
brake uni ts.
The hydraul i c system i s a three channel desi gn.
The front wheel brakes are control l ed i ndi vi dual l y
and the rear wheel brakes i n tandem (Fi g. 1). The
ABS el ectri cal system i s separate from other el ectri -
cal ci rcui ts i n the vehi cl e. A speci al l y programmed
control l er anti l ock brake uni t operates the system
components.
ABS system major components i ncl ude:
Control l er Anti l ock Brakes (CAB)
Hydraul i c Control Uni t (HCU)
Wheel Speed Sensors (WSS)
Accel erati on Swi tch
ABS Warni ng Li ght
ANTILOCK BRAKE SYSTEM
Battery vol tage i s suppl i ed to the CAB i gni ti on ter-
mi nal when the i gni ti on swi tch i s turned to Run posi -
ti on. The CAB performs a system i ni ti al i zati on
procedure at thi s poi nt. I ni ti al i zati on consi sts of a
stati c and dynami c sel f check of system el ectri cal
components.
The stati c check occurs after the i gni ti on swi tch i s
turned to Run posi ti on. The dynami c check occurs
when vehi cl e road speed reaches approxi matel y 10
kph (6 mph). Duri ng the dynami c check, the CAB
bri efl y cycl es the pump and sol enoi ds to veri fy oper-
ati on.
I f an ABS component exhi bi ts a faul t duri ng i ni -
ti al i zati on, the CAB i l l umi nates the amber warni ng
l i ght and regi sters a faul t code i n the mi croprocessor
memory.
NORMAL BRAKING
The CAB moni tors wheel speed sensor i nputs con-
ti nuousl y whi l e the vehi cl e i s i n moti on. However,
Fig. 1 Antilock Brake System
MASTER CYLINDER AND RESERVOIR POWER BRAKE BOOSTER ACCELERATION SWITCH CAB WIRES TO WHEEL SPEED SENSORS RIGHT REAR WHEEL LEFT REAR WHEEL LEFT FRONT WHEEL RIGHT FRONT WHEEL HYDRAULIC BRAKE LINES TO WHEELS HCU HARNESS HCU COMBINATION VALVE
ZG BRAKES 5 - 35
the CAB wi l l not acti vate any ABS components as
l ong as sensor i nputs and the accel erati on swi tch
i ndi cate normal braki ng.
Duri ng normal braki ng, the master cyl i nder, power
booster and wheel brake uni ts al l functi on as they
woul d i n a vehi cl e wi thout ABS. The HCU compo-
nents are not acti vated.
ANTILOCK BRAKING
The purpose of the anti l ock system i s to prevent
wheel l ockup duri ng peri ods of hi gh wheel sl i p. Pre-
venti ng l ockup hel ps mai ntai n vehi cl e braki ng acti on
and steeri ng control .
The anti l ock CAB acti vates the system whenever
sensor si gnal s i ndi cate peri ods of hi gh wheel sl i p.
Hi gh wheel sl i p can be descri bed as the poi nt where
wheel rotati on begi ns approachi ng 20 to 30 percent of
actual vehi cl e speed duri ng braki ng. Peri ods of hi gh
wheel sl i p occur when brake stops i nvol ve hi gh pedal
pressure and rate of vehi cl e decel erati on.
The anti l ock system prevents l ockup duri ng hi gh
sl i p condi ti ons by modul ati ng fl ui d appl y pressure to
the wheel brake uni ts.
Brake fl ui d appl y pressure i s modul ated accordi ng
to wheel speed, degree of sl i p and rate of decel era-
ti on. A sensor at each wheel converts wheel speed
i nto el ectri cal si gnal s. These si gnal s are transmi tted
to the CAB for processi ng and determi nati on of
wheel sl i p and decel erati on rate.
The ABS system has three fl ui d pressure control
channel s. The front brakes are control l ed separatel y
and the rear brakes i n tandem. A speed sensor i nput
si gnal i ndi cati ng a hi gh sl i p condi ti on acti vates the
CAB anti l ock program.
Two sol enoi d val ves are used i n each anti l ock con-
trol channel . The val ves are al l l ocated wi thi n the
HCU val ve body and work i n pai rs to ei ther i ncrease,
hol d, or decrease appl y pressure as needed i n the
i ndi vi dual control channel s.
The sol enoi d val ves are not stati c duri ng anti l ock
braki ng. They are cycl ed conti nuousl y to modul ate
pressure. Sol enoi d cycl e ti me i n anti l ock mode can be
measured i n mi l l i seconds.
CONTROLLER ANTILOCK BRAKES
The CAB i s mounted to the HCU and operates the
ABS system (Fi g. 2) separate from other vehi cl e el ec-
tri cal ci rcui ts. CAB vol tage source i s through the
i gni ti on swi tch i n the RUN posi ti on.
The CAB contai ns dual mi croprocessors. A l ogi c
bl ock i n each mi croprocessor recei ves i denti cal sensor
si gnal s. These si gnal s are processed and compared
si mul taneousl y.
The CAB contai ns a sel f check program that i l l u-
mi nates the ABS warni ng l i ght when a system faul t
i s detected. Faul ts are stored i n a di agnosti c program
memory and are accessi bl e wi th the DRB scan tool .
ABS faul ts remai n i n memory unti l cl eared, or
unti l after the vehi cl e i s started approxi matel y 50
ti mes. Stored faul ts are not erased i f the battery i s
di sconnected.
HYDRAULIC CONTROL UNIT
The HCU consi sts of a val ve body, pump body,
accumul ators, pump motor, and wi re harnesses (Fi g.
2).
The pump, motor, and accumul ators are combi ned
i nto an assembl y attached to the val ve body. The
accumul ators store the extra fl ui d rel eased to the
system for ABS mode operati on. The pump provi des
the fl ui d vol ume needed and i s operated by a DC
type motor. The motor i s control l ed by the CAB.
The val ve body contai ns the sol enoi d val ves. The
val ves modul ate brake pressure duri ng anti l ock brak-
i ng and are control l ed by the CAB.
The HCU provi des three channel pressure control
to the front and rear brakes. One channel control s
the rear wheel brakes i n tandem. The two remai ni ng
channel s control the front wheel brakes i ndi vi dual l y.
Duri ng anti l ock braki ng, the sol enoi d val ves are
opened and cl osed as needed. The val ves are not
stati c. They are cycl ed rapi dl y and conti nuousl y to
modul ate pressure and control wheel sl i p and decel -
erati on.
Duri ng normal braki ng, the HCU sol enoi d val ves
and pump are not acti vated. The master cyl i nder and
power booster operate the same as a vehi cl e wi thout
an ABS brake system.
Duri ng anti l ock braki ng, sol enoi d val ve pressure
modul ati on occurs i n three stages, pressure i ncrease,
pressure hol d, and pressure decrease. The val ves are
al l contai ned i n the val ve body porti on of the HCU.
Pressure Decrease
The outl et val ve i s opened and the i nl et val ve i s
cl osed duri ng the pressure decrease cycl e.
Fig. 2 Controller Antilock Brakes
HCU MOTOR CAB
5 - 36 BRAKES ZG
A pressure decrease cycl e i s i ni ti ated when speed
sensor si gnal s i ndi cate hi gh wheel sl i p at one or
more wheel s. At thi s poi nt, the CAB cl oses the i nl et
then opens the outl et val ve, whi ch al so opens the
return ci rcui t to the accumul ators. Fl ui d pressure i s
al l owed to bl eed off (decrease) as needed to prevent
wheel l ock.
Once the peri od of hi gh wheel sl i p has ended, the
CAB cl oses the outl et val ve and begi ns a pressure
i ncrease or hol d cycl e as needed.
Pressure Hold
Both sol enoi d val ves are cl osed i n the pressure
hol d cycl e. Fl ui d appl y pressure i n the control chan-
nel i s mai ntai ned at a constant rate. The CAB mai n-
tai ns the hol d cycl e unti l sensor i nputs i ndi cate a
pressure change i s necessary.
Pressure Increase
The i nl et val ve i s open and the outl et val ve i s
cl osed duri ng the pressure i ncrease cycl e. The pres-
sure i ncrease cycl e i s used to counteract unequal
wheel speeds. Thi s cycl e control s re-appl i cati on of
fl ui d appl y pressure due to changi ng road surfaces or
wheel speed.
WHEEL SPEED SENSORS AND TONE WHEEL
A speed sensor i s used at each wheel . The front
sensors are mounted to the steeri ng knuckl es. The
rear sensors at the outboard end of the axl e.
The sensors convert wheel speed i nto a smal l AC
el ectri cal si gnal . Thi s si gnal i s transmi tted to the
CAB. The CAB converts the AC si gnal i nto a di gi tal
si gnal for each wheel . Thi s vol tage i s generated by
magneti c i nducti on when a tone wheel passes by the
stati onary magneti c of the wheel speed sensor.
A gear type tone ri ng serves as the tri gger mecha-
ni sm for each sensor. The tone ri ngs are mounted at
the outboard ends of the front and rear axl e shafts.
Di fferent sensors are used at the front and rear
wheel s (Fi g. 3). The front/rear sensors have the same
el ectri cal val ues but are not i nterchangeabl e. The
sensors have a resi stance between 900 and 1300
ohms.
SPEED SENSOR AIR GAP
FRONT SENSOR
Front sensor ai r gap i s fi xed and not adjustabl e.
Onl y rear sensor ai r gap i s adjustabl e.
Al though front ai r gap i s not adjustabl e, i t can be
checked i f di agnosi s i ndi cates thi s i s necessary. Front
ai r gap shoul d be 0.36 to 1.5 mm (0.014 to 0.059 i n.).
I f gap i s i ncorrect, the sensor i s ei ther l oose, or dam-
aged.
REAR SENSOR
A rear sensor ai r gap adjustment i s onl y needed
when rei nstal l i ng an ori gi nal sensor. Repl acement
sensors have an ai r gap spacer attached to the sensor
pi ckup face. The spacer establ i shes correct ai r gap
when pressed agai nst the tone ri ng duri ng i nstal l a-
ti on. As the tone ri ng rotates, i t peel s the spacer off
the sensor to create the requi red ai r gap. Rear sensor
ai r gap i s 0.92 to 1.275 mm (0.036 to 0.05 i n.).
COMBINATION VALVE
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e. I t must be
repl aced i f di agnosi s i ndi cates thi s i s necessary.
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs are
made.
The rear proporti oni ng val ve i s used to bal ance
front-rear brake acti on. The val ve al l ows normal
fl ui d fl ow duri ng moderate effort brake stops. The
val ve onl y control s (meters) fl ui d fl ow duri ng hi gh
effort brake stops.
Fig. 3 Wheel Speed Sensors
FRONT SENSOR REAR SENSOR PICK UP FACE PICK UP FACE
ZG BRAKES 5 - 37
ACCELERATION SWITCH
The accel erati on swi tch i s l ocated under the rear
seat. The swi tch (Fi g. 4), provi des an addi ti onal vehi -
cl e decel erati on reference duri ng 4WD operati on. The
swi tch i s moni tored by the CAB at al l ti mes. The
swi tch reference si gnal i s uti l i zed by the CAB when
al l wheel s are decel erati ng at the same speed.
ABS SYSTEM RELAYS
The ABS system has two rel ays, whi ch are the
mai n and motor pump rel ays. The mai n rel ay i s used
for the sol enoi d val ves and CAB. The mai n rel ay i s
connected to the CAB at the power control rel ay ter-
mi nal . The motor pump rel ay i s used for the motor
pump onl y. The pump motor rel ay starts/stops the
pump motor when si gnal ed by the CAB.
ABS WARNING LAMP
The amber ABS warni ng l amp i s l ocated i n the
i nstrument cl uster. The l amp i l l umi nates at start-up
to perform a sel f check. The l amp goes out when the
sel f check program determi nes the system i s operat-
i ng normal . I f an ABS component exhi bi ts a faul t the
CAB wi l l i l l umi nate the l amp and regi ster a troubl e
code i n the mi croprocessor. The l amp i s control l ed by
the CAB. The CAB control s the l amp by di rectl y
groundi ng the ci rcui t.
ANTILOCK BRAKES
The ABS brake system performs several sel f-tests
every ti me the i gni ti on swi tch i s turned on and the
vehi cl e i s dri ven. The CAB moni tors the systems
i nput and output ci rcui ts to veri fy the system i s oper-
ati ng correctl y. I f the on board di agnosti c system
senses that a ci rcui t i s mal functi oni ng the system
wi l l set a troubl e code i n i ts memory.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag-
nostic Manual.
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM
ABS system bl eedi ng requi res conventi onal bl eed-
i ng methods pl us use of the DRB scan tool . The pro-
cedure i nvol ves performi ng a base brake bl eedi ng,
fol l owed by use of the scan tool to cycl e and bl eed the
HCU pump and sol enoi ds. A second base brake bl eed-
i ng procedure i s then requi red to remove any ai r
remai ni ng i n the system.
(1) Perform base brake bl eedi ng. Refer to base
brake secti on for procedure.
(2) Connect scan tool to the Data Li nk Connector.
(3) Sel ect ANTI LOCK BRAKES, fol l owed by MI S-
CELLANEOUS, then ABS BRAKES. Fol l ow the
i nstructi ons di spl ayed. When scan tool di spl ays TEST
COMPLETE, di sconnect scan tool and proceed.
(4) Perform base brake bl eedi ng a second ti me.
Refer to base brake secti on for procedure.
(5) Top off master cyl i nder fl ui d l evel and veri fy
proper brake operati on before movi ng vehi cl e.
ANTILOCK BRAKES
REMOVAL
(1) Remove negati ve battery cabl e from the bat-
tery.
(2) Remove ai r cl eaner housi ng.
(3) Remove wi ndshi el d reservoi r mounti ng bol ts
and move the reservoi r to the si de.
(4) Remove steeri ng gear shi el d.
(5) Pul l CAB harness connector rel ease out and
remove connector (Fi g. 5).
(6) Remove the brake l i nes from the HCU.
(7) Remove HCU/CAB bracket mounti ng nuts (Fi g.
6).
(8) Remove HCU/CAB assembl y from the vehi cl e.
(9) Remove bracket bol ts from the HCU/CAB
assembl y.
INSTALLATION
(1) I nstal l bracket onto the HCU/CAB assembl y.
(2) I nstal l HCU/CAB assembl y i n the vehi cl e and
ti ghten mounti ng nuts to 12 Nm (9 ft. l bs.).
Fig. 4 Acceleration Switch
SWITCH PART NUMBER ARROW INDICATES FRONT OF SWITCH FOR PROPER MOUNTING
5 - 38 BRAKES ZG
(3) I nstal l the brake l i nes to the HCU and ti ghten
to 16 Nm (12 ft. l bs.).
(4) I nstal l CAB harness connector and push-i n
connector rel ease.
(5) I nstal l steeri ng gear shi el d.
(6) I nstal l wi ndshi el d reservoi r and mounti ng
bol ts.
(7) I nstal l ai r cl eaner housi ng.
(8) I nstal l negati ve battery cabl e to the battery.
(9) Bl eed compl ete brake system.
FRONT WHEEL SPEED SENSOR
REMOVAL
(1) Turn i gni ti on swi tch to OFF posi ti on.
(4) Remove bol t attachi ng front sensor to steeri ng
knuckl e (Fi g. 7).
(5) Di sengage sensor wi re from brackets on steer-
i ng knuckl e and frame member (Fi g. 8) and (Fi g. 9).
(6) Unseat grommet that secures sensor wi re i n
fender panel .
(7) I n engi ne compartment, di sconnect sensor wi re
connector at harness pl ug.
Fig. 5 CAB Connector Release
HCU/CAB ASSEMBLY CONNECTOR RELEASE
Fig. 6 HCU/CAB Assembly
HCU/CAB ASSEMBLY MOTOR FWD MOUNTING BRACKET
Fig. 7 Sensor Location
FRONT SENSOR SENSOR WIRE STEERING KNUCKLE TONE WHEEL
Fig. 8 Sensor Wire Routing
FRONT SENSOR WIRE STEERING KNUCKLE SENSOR WIRE BRACKETS FRAME MEMBER
Fig. 9 Sensor Wire Grommet
FENDER PANEL GROMMET FRONT WHEEL SENSOR WIRE SHOCK ABSORBER FRONT BRAKE HOSE AND LINE
ZG BRAKES 5 - 39
(8) Remove sensor and wi re assembl y.
INSTALLATION
(1) Appl y Mopar Lock N Seal or Locti te 242 to
sensor attachi ng bol t. Use new sensor bol t i f ori gi nal
bol t i s worn or damaged.
(2) Posi ti on sensor on steeri ng knuckl e. Seat sen-
sor l ocati ng tab i n hol e i n knuckl e and i nstal l sensor
attachi ng bol t fi nger ti ght.
(3) Ti ghten sensor bol t to 14 Nm (11 ft. l bs.).
(4) Route sensor wi re from steeri ng knuckl e to
fender panel .
(5) Engage grommets on sensor wi re i n brackets
on body, chassi s, frame, and steeri ng knuckl e.
(6) Check sensor wi re routi ng. Be sure wi re i s
cl ear of al l chassi s components and i s not twi sted or
ki nked at any spot.
(7) Seat sensor wi re i n body grommet and seat
grommet i n fender panel .
(8) Connect sensor wi re to harness i n engi ne com-
partment.
REAR WHEEL SPEED SENSOR
REMOVAL
(1) Rai se and fol d rear seat forward. Then move
carpeti ng asi de for access to rear sensor connectors.
(2) Di sconnect rear sensor wi res at harness con-
nectors.
(3) Push sensor wi res and grommets through fl oor-
pan hol es.
(4) Rai se vehi cl e and remove wheel and ti re
assembl e.
(5) Remove di sc brake cal i per and rotor.
(6) Di sengage sensor wi re from axl e and chassi s
brackets and from brake l i ne retai ners.
(7) Remove bol t attachi ng sensor to spl ash shi el d
bracket (Fi g. 10).
(8) Remove sensor from spl ash shi el d bracket.
INSTALLATION
(1) I nsert sensor through spl ash shi el d hol e.
(2) Appl y Mopar Lock N Seal or Locti te 242 to
ori gi nal sensor bol t. Use new bol t i f ori gi nal i s worn
or damaged.
(3) I nstal l sensor bol t fi nger ti ght onl y at thi s
ti me.
(4) I f original sensor i s bei ng i nstal l ed or
adjusted, remove any remai ni ng pi eces of cardboard
spacer from sensor pi ckup face. Set ai r gap to 0.92 to
1.275 mm (0.036 to 0.05 i n.) wi th feel er gauge (Fi g.
11). Ti ghten sensor bol t to 14 Nm (11 ft. l bs.).
(5) I f new sensor i s bei ng i nstal l ed, push card-
board spacer on sensor face agai nst tone ri ng. Then
ti ghten sensor bol t to 14 Nm (11 ft. l bs.). Correct ai r
gap wi l l be establ i shed as tone ri ng rotates and peel s
spacer off sensor face.
(6) Route sensor wi res to rear seat area.
(7) Feed sensor wi res through fl oorpan access hol e
and seat sensor grommets i n fl oorpan.
(8) Secure sensor wi re i n brackets and i n retai ners
on rear brake l i nes. Veri fy that sensor wi re i s secure
and cl ear of rotati ng components.
(9) I nstal l rotor, cal i per and wheel , l ower vehi cl e.
(10) Fol d rear seat and carpet forward for access
to sensor wi res and connectors.
(11) Connect sensor wi res to harness connectors.
(12) Reposi ti on carpet and fol d rear seat down.
ACCELERATION SWITCH
REMOVAL
(1) Turn i gni ti on swi tch to the OFF posi ti on.
Fig. 10 Sensor Mounting Bolt
SENSOR MOUNTING BOLT
Fig. 11 Air Gap On Rear Sensor
WHEEL SPEED SENSOR TONE WHEEL
5 - 40 BRAKES ZG
(3) Ti l t rear seat assembl y forward for access to
the swi tch.
(4) Di sconnect swi tch harness (Fi g. 12).
(5) Remove bol ts attachi ng swi tch to bracket and
remove the swi tch.
INSTALLATION
CAUTION: The mercury switch inside the accelera-
tion switch, will only function properly if the locat-
ing arrow is pointing to the front of the vehicle (Fig.
13).
(1) Note posi ti on of l ocati ng arrow on swi tch. Posi -
ti on swi tch so arrow faces forward.
(2) Posi ti on swi tch i n mounti ng bracket.
(3) I nstal l and ti ghten swi tch attachi ng bol ts to
2-4 Nm (17-32 i n. l bs.).
(4) Connect harness to swi tch. Be sure harness
connector i s fi rml y seated.
(5) Move rear seat back to normal posi ti on.
ANTILOCK BRAKE
DISASSEMBLY
(1) Remove pump motor connector from the CAB.
(2) Remove CAB mounti ng screws from the HCU
(Fi g. 14).
(3) Remove CAB from the HCU.
Fig. 12 Acceleration Switch Mounting
SENSOR BOLT ACCELERATION SENSOR REAR SENSOR CONNECTORS AND WIRES B-PILLAR DRIVER SIDE SILL FWD ACCELERATION SENSOR FLOORPAN RISER SENSOR BRACKET FWD BRACKET SCREW
Fig. 13 Acceleration Switch
SWITCH PART NUMBER ARROW INDICATES FRONT OF SWITCH FOR PROPER MOUNTING
Fig. 14 CAB Mounting Screws
MOUNTING SCREWS CAB
ZG BRAKES 5 - 41
ASSEMBLY
(1) I nstal l the CAB onto the HCU.
(2) I nstal l the CAB mounti ng screws and ti ghten
to 1.8 Nm (16 i n. l bs.).
(3) I nstal l pump motor connector to the CAB.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Acceleration Sensor
Sensor Bol t . . . . . . . . . . . . 8-9 Nm (71-83 i n. l bs.)
Bracket Bol t . . . . . . . . . . . 1-2 Nm (13-18 i n. l bs.)
Hydraulic Control Unit/Controller Antilock
Brakes
Mounti ng Nuts . . . . . . . . . . . . . 12 Nm (9 ft. l bs.)
Brake Li nes . . . . . . . . . . . . . . . 16 Nm (12 ft. l bs.)
CAB Screws . . . . . . . . . . . . . . 1.8 Nm (16 i n. l bs.)
Wheel Speed Sensors
Front Sensor Bol t . . . . . . . . . . . 4-6 (34-50 i n. l bs.)
Rear Sensor Bol t . . . . 12-14 Nm (106-124 i n. l bs.)
5 - 42 BRAKES ZG
CLUTCH
CONTENTS
page page
GENERAL INFORMATION
CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . 1
CLUTCH HYDRAULIC SYSTEM . . . . . . . . . . . . . 1
CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . 1
FLYWHEEL RING GEAR . . . . . . . . . . . . . . . . . . . 5
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
CLUTCH COMPONENTS
The cl utch mechani sm consi sts of a si ngl e, dry-type
cl utch di sc and a di aphragm styl e cl utch cover. A
hydraul i c l i nkage i s used to operate the cl utch di sc
and cover. The cl utch components are very si mi l ar to
those used i n gas engi ne model s.
A pi l ot beari ng i s used to support the transmi ssi on
i nput shaft. The beari ng i s seated i n a separate,
removabl e housi ng bol ted to the fl ywheel hub.
CLUTCH HYDRAULIC SYSTEM
The cl utch hydraul i c system shoul d not requi re
addi ti onal fl ui d under normal ci rcumstances.
NOTE: The reservoir fluid level will actually
increase as normal clutch wear occurs. For this rea-
son, it is important to avoid over filling, or remov-
ing fluid from the reservoir.
I f i nspecti on i ndi cates addi ti onal fl ui d i s needed,
add fl ui d from a seal ed contai ner onl y. Use Mopar
brake fl ui d, or an equi val ent meeti ng standards SAE
J1703 and DOT 3. Do not use any other type of fl ui d.
CLUTCH COVER AND DISC
REMOVAL
(1) Remove transmi ssi on and transfer case, i f
equi pped. (Refer to Group 21, Transmi ssi on And
Transfer Case.)
(2) I f ori gi nal cl utch cover wi l l be rei nstal l ed, mark
posi ti on of cover on fl ywheel for assembl y reference.
Use pai nt or scri be for thi s purpose.
(3) I f cl utch cover i s to be repl aced, cover bol ts can
be removed i n any sequence. However, i f ori gi nal
cover wi l l be rei nstal l ed, l oosen cover bol ts evenl y i n
a star pattern to rel i eve spri ng tensi on equal l y. Thi s
i s necessary to avoi d warpi ng the cover.
(4) Remove cl utch cover bol ts and remove cover
and di sc (Fi g. 1).
ZG CLUTCH 6 - 1
INSTALLATION
(1) Li ghtl y scuff sand fl ywheel face wi th 180 gri t
emery cl oth. Then cl ean surface wi th brake or carbu-
retor cl eaner.
(2) Li ghtl y l ubri cate pi l ot beari ng wi th Mopar
hi gh temperature beari ng grease.
(3) Check free operati on of cl utch di sc by sl i di ng
di sc onto transmi ssi on output shaft spl i nes. Di sc
shoul d sl i de onto spl i nes freel y wi thout bi ndi ng.
(4) Posi ti on cl utch di sc on fl ywheel . Be sure si de of
di sc marked fl ywheel si de i s posi ti oned agai nst fl y-
wheel (Fi g. 2). I f di sc i s not marked, be sure fl at si de
of di sc hub i s pl aced toward the fl ywheel .
(5) I nsert cl utch al i gnment tool (Fi g. 3) i n cl utch
di sc and pi l ot beari ng.
(6) Posi ti on cl utch cover over di sc and on fl ywheel .
(7) I nstal l cl utch cover bol ts fi nger ti ght.
(8) Starti ng wi th the bol ts marked P on the cover
fi rst, ti ghten cl utch cover bol ts i n a star pattern to 50
Nm torque.
(9) Appl y l i ght coat of Mopar hi gh temperature
beari ng grease to pi l ot beari ng and spl i nes of trans-
mi ssi on i nput shaft.
CAUTION: Do not over-lubricate as this will result
in grease contamination of the disc.
(10) I nstal l transmi ssi on.
Fig. 1 Clutch Components (VM Diesel)
Fig. 2 Clutch Disc Position
6 - 2 CLUTCH ZG
PILOT BEARING
REMOVAL
(1) Remove transmi ssi on and transfer case. (Refer
to Group 21, Transmi ssi ons And Transfer Case.)
(2) Remove cl utch cover and di sc.
(3) Remove the four bol ts that attach the pi l ot
beari ng retai ner to the fl ywheel (Fi g. 4).
(4) Remove the pi l ot beari ng retai ner.
(5) Support the beari ng retai ner on two wood
bl ocks.
(6) Remove the pi l ot beari ng wi th a sui tabl e si zed
socket and extensi on (Fi g. 5). Use mal l et to tap bear-
i ng out of retai ner.
INSTALLATION
CAUTION: The bearing can be installed incorrectly
if care is not exercised. Check bearing position
before installing it Make sure the bearing seal and
the letters on the bearing will both be facing out
(toward the clutch) after installation.
(1) I nstal l new pi l ot beari ng wi th hammer and tool
handl e C-4171 (Fi g. 6). Seat beari ng fl ush wi th l ower
Fig. 3 Clutch Disc AlignmentTypical
Fig. 4 Pilot Bearing Retainer Bolt Removal/
Installation
Fig. 5 Pilot Bearing Removal
Fig. 6 Pilot Bearing Installation
Fig. 7 Pilot Bearing Seated In Retainer
ZG CLUTCH 6 - 3
edge of chamfer i n retai ner bore (Fi g. 7). Reposi ti on
beari ng i f necessary.
(2) I nstal l beari ng retai ner and ti ghten bol ts.
(3) Lubri cate pi l ot beari ng wi th Mopar hi gh tem-
perature wheel beari ng grease.
(4) Li ghtl y scuff sand fl ywheel surface wi th 180
gri t emery cl oth. Cl ean the surface wi th Mopar
brake or carburetor cl eaner.
(5) I nstal l cl utch di sc and cover as descri bed i n
thi s secti on
(6) I nstal l transmi ssi on and transfer case.
FLYWHEEL
REMOVAL
(1) Remove transmi ssi on and cl utch housi ng.
(Refer to Group 21, Transmi ssi on And Transfer
Case.)
(2) Remove cl utch cover and di sc as descri bed i n
thi s secti on.
(3) Remove bol ts that attach pi l ot beari ng retai ner
to fl ywheel .
(4) Remove pi l ot beari ng and retai ner.
(5) Remove fl ywheel bol ts.
(6) Grasp fl ywheel fi rml y and work i t off the
crankshaft fl ange (si de to si de or up and down). Be
sure to mai ntai n a fi rm gri p as the fl ywheel i s heavy.
(7) Remove the o-ri ng from the crankshaft fl ange,
or the mounti ng shoul der of the fl ywheel (Fi g. 9).
(8) Cl ean the fl ywheel i n sol vent.
INSPECTION
Exami ne fl ywheel mounti ng surfaces, cl utch con-
tact surface, and ri ng gear. Check condi ti on of fl y-
wheel hub and attachi ng bol ts. Repl ace fl ywheel i f
hub exhi bi ts cracks i n the area of attachi ng bol t
hol es. Repl ace ri ng gear i f the teeth are damaged.
Resurface the fl ywheel i f the cl utch contact surface i s
scored or rough (refer to fl ywheel fi ni shi ng and ri ng
gear repl acement i nformati on i n thi s secti on.
Check fl ywheel runout i f mi sal i gnment i s sus-
pected. Runout shoul d not exceed 0.08 mm. Measure
fl ywheel face runout wi th a di al i ndi cator (Fi g. 8).
Mount the i ndi cator on a stud i nstal l ed i n the engi ne
bl ock or i n one of the fl ywheel attachi ng bol t hol es.
Face runout can be corrected by resurfaci ng i f neces-
sary. Surface gri ndi ng equi pment i s recommended for
thi s purpose. Stock removal shoul d not exceed 0.25
mm.
INSTALLATION
(1) Cl ean crankshaft fl ange before mounti ng the
fl ywheel . Di rt or grease on fl ange surface may cock
fl ywheel causi ng run-out.
(2) I nstal l new o-ri ng i n the fl ywheel mounti ng
fl ange (Fi g. 9). Use grease to hol d the ri ng i n pl ace.
(3) Mount fl ywheel to crankshaft and al i gn the
bol t hol es.
Fig. 8 Checking Flywheel Runout
Fig. 9 Flywheel Mounting (VM Diesel)
Fig. 10 Flywheel Bolt Tightening Pattern
6 - 4 CLUTCH ZG
(4) I nstal l and ti ghten new fl ywheel bol ts as fol -
l ows:
(a) Lubri cate bol t threads wi th engi ne oi l .
(b) I nstal l and ti ghten bol ts to i ni ti al torque of
20 Nm. Ti ghten bol ts di agonal l y i n pai rs (Fi g. 10).
(c) Ti ghten each bol t and addi ti onal 60 turn.
Conti nue ti ghteni ng bol ts i n smal l i ncrements to
fi nal torque of 130 Nm.
(5) I nstal l cl utch di sc and cover (refer to procedure
i n thi s secti on).
FLYWHEEL RING GEAR
REMOVAL
(1) Remove the transmi ssi on and transfer case.
(Refer to Group 21, Transmi ssi on And Transfer
Case.)
(2) Remove the cl utch cover.
(3) Remove the cl utch pl ate.
(4) Remove the fl ywheel .
(5) Mark posi ti on of the ol d gear for al i gnment ref-
erence. Use a carbi de ti pped scri be to mark gear l oca-
ti on on fl ywheel .
(6) Wear protecti ve goggl es or approved safety
gl asses.
(7) Remove the ol d gear by cutti ng most of the way
through i t at one poi nt. Use an abrasi ve cut off wheel
for thi s purpose. Break the ri ng gear at cut wi th a
hammer and a col d chi sel or punch
(8) Ri ng gear i s shri nk fi t on fl ywheel . Thi s means
the gear must be expanded by heati ng i n order to
i nstal l i t.
NOTE: The method of heating and expanding the
new ring gear is extremely important. Every surface
of the gear must be heated at the same time to pro-
duce uniform expansion. An oven or similar
enclosed heating device must be used. Temperature
required for uniform expansion is approximately
350-375.
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
INSTALLATION
(1) Posi ti on and i nstal l the heated ri ng gear on the
fl ywheel :
(a) Wear heat resi stant gl oves to handl e the hot
ri ng gear.
(b) Al i gn the ri ng gear on the fl ywheel evenl y.
(c) Use hammer and brass dri ft to tap ri ng gear
onto the fl ywheel .
(d) Seat gear on fl ywheel
(2) Al l ow the ri ng gear to cool down before i nstal -
l ati on on the engi ne. Pl ace fl ywheel on work bench
and l et i t cool i n normal shop ai r.
(3) I nstal l fl ywheel and torque bol ts to 130 Nm.
(4) I nstal l cl utch cover and di sc. Refer to procedure
i n thi s secti on.
CAUTION: Do not use water or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air will distort or crack the
new gear.
SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION TORQUE
Clutch Cover to Flywheel
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Clutch Housing to Transmission
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Flywheel to Crankshaft
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Nm
Pilot Bearing Retainer to Flywheel/Crankshaft
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Clutch Housing to Engine
Top (2) Bol ts . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Mi ddl e (2) Bol ts . . . . . . . . . . . . . . . . . . . . . 58 Nm
Bottom (2) Bol ts . . . . . . . . . . . . . . . . . . . . 75 Nm
SPECIAL TOOLS
SPECIAL TOOLS
Universal HandleC-4171
ZG CLUTCH 6 - 5
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLING SYSTEM COMPONENTS . . . . . . . . . . 2
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SYSTEM COOLANT ROUTING . . . . . . . . . . . . . 2
WATER PUMP BYPASS HOSE5.2/5.9L V-8
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCESSORY DRIVE BELT TENSION . . . . . . . . . 4
AUTOMATIC TRANSMISSION OIL COOLERS . . 3
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . 5
COOLANT RESERVE/OVERFLOW SYSTEM . . . 3
COOLANT SELECTION-ADDITIVES . . . . . . . . . . 5
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . 6
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 4
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . 5
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . 7
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . 14
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . 9
LOW COOLANT LEVEL-AERATION . . . . . . . . . 21
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . 8
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . 13
PRESSURE TESTING RADIATOR CAP . . . . . . 20
RADIATOR CAP-TO-FILLER NECK SEAL
PRESSURE RELIEF CHECK . . . . . . . . . . . . . 20
RADIATOR COOLANT FLOW CHECK . . . . . . . 18
SERPENTINE DRIVE BELT DIAGNOSIS . . . . . . 10
TESTING COOLING SYSTEM FOR LEAKS . . . 18
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 10
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . 19
WATER PUMP TESTS . . . . . . . . . . . . . . . . . . . . 9
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT . . . . . . . . . . . 21
COOLANT LEVEL CHECKSERVICE . . . . . . . 21
COOLING SYSTEM CLEANING/REVERSE
FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DRAINING AND FILLING COOLING SYSTEM . . 21
ROUTINE COOLANT LEVEL CHECK . . . . . . . . 21
EXTERNAL TRANSMISSION OIL COOLER
AUXILIARY . . . . . . . . . . . . . . . . . . . . . . . . . . 23
AUTOMATIC BELT TENSIONER . . . . . . . . . . . . 41
BELT REPLACEMENT/ADJUSTMENT . . . . . . . 39
COOLING SYSTEM FAN 4.0L ENGINE . . . . . . . 42
COOLING SYSTEM FAN 5.2/5.9L ENGINES . . . 43
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . 38
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
THERMOSTAT 4.0L ENGINE . . . . . . . . . . . . . . 29
THERMOSTAT 5.2/5.9L ENGINES . . . . . . . . . . 30
WATER PUMP 4.0L ENGINE . . . . . . . . . . . . . . 24
WATER PUMP 5.2/5.9L ENGINES . . . . . . . . . . 26
WATER PUMP BYPASS HOSE . . . . . . . . . . . . . 36
FAN BLADE INSPECTION . . . . . . . . . . . . . . . . 44
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . 44
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
WATER PUMP INSPECTION . . . . . . . . . . . . . . 44
SPECIFICATIONS
COOLING SYSTEM CAPACITIES . . . . . . . . . . . 44
DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . 44
INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 45
SPECIAL TOOLS
SPECIAL TOOLSCOOLING . . . . . . . . . . . . . . 45
GENERAL INFORMATION
ENGINE ACCESSORY DRIVE BELTS
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to water pump rotat-
ing in wrong direction. Refer to the appropriate
engine Belt Schematic in this Group for the correct
belt routing. Or, refer to the Belt Routing Label
located in the engine compartment.
COOLING SYSTEM
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e. I t al so
mai ntai ns normal operati ng temperature and pre-
vents overheati ng.
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant throughout the system.
ZG COOLING SYSTEM 7 - 1
An opti onal factory i nstal l ed maxi mum duty cool -
i ng package i s avai l abl e on most model s. Thi s pack-
age wi l l provi de addi ti onal cool i ng capaci ty for
vehi cl es used under extreme condi ti ons such as
trai l er towi ng i n hi gh ambi ent temperatures.
COOLING SYSTEM COMPONENTS
The cool i ng system consi sts of:
A radi ator
Cool i ng fan
Thermal vi scous fan dri ve
Fan shroud
Radi ator pressure cap
Thermostat
Cool ant reserve/overfl ow system
Transmi ssi on oi l cool er (i f equi pped wi th an
automati c transmi ssi on)
Cool ant
Water pump
Hoses and hose cl amps
Accessory dri ve bel t
SYSTEM COOLANT ROUTING
For cool i ng system routi ngs refer to (Fi g. 1) (Fi g.
2).
Fig. 1 Engine Cooling System4.0LEngineTypical
HEATER CORE TO COOLANT RESERVE/ OVERFLOW TANK THERMOSTAT HOUSING RADIATORWATER PUMP
Fig. 2 Engine Cooling System5.2/5.9LEngineTypical
HEATER BYPASS CROSSFLOW RADIATOR BYPASS THERMOSTAT CLOSEDHIGH FLOW THERMOSTAT OPENLOW FLOW
7 - 2 COOLING SYSTEM ZG
WATER PUMP BYPASS HOSE 5. 2/5. 9L V-8
ENGINES
A water pump bypass hose (Fi g. 3) i s used between
the i ntake mani fol d and water pump on al l 5.2/5.9L
V-8 engi nes.
COOLANT
The cool i ng system i s desi gned around the cool ant.
Cool ant fl ows through the engi ne water jackets
absorbi ng heat produced duri ng engi ne operati on.
The cool ant carri es heat to the radi ator and heater
core. Here i t i s transferred to ambi ent ai r passi ng
through the radi ator and heater core fi ns. The cool -
ant al so removes heat from the automati c transmi s-
si on fl ui d i n vehi cl es equi pped wi th an automati c
transmi ssi on.
RADIATOR
Al l vehi cl es are equi pped wi th a cross fl ow type
radi ator wi th pl asti c si de tanks.
Pl asti c tanks, whi l e stronger than brass, are sub-
ject to damage by i mpact, such as from tool s or
wrenches. Handl e radi ator wi th care.
AUTOMATIC TRANSMISSION OIL COOLERS
There are three types of automati c transmi ssi on oi l
cool ers:
An oi l -to-cool ant type. Thi s i s suppl i ed as stan-
dard equi pment on vehi cl es wi th an automati c trans-
mi ssi on. I t i s mounted i n the radi ator outl et tank.
An external auxi l i ary oi l -to-ai r cool er. Thi s i s
suppl i ed as opti onal equi pment. I t i s mounted i n
front of the radi ator and ai r condi ti oni ng condenser
and behi nd the gri l l e.
An i nternal hi gh capaci ty/hi gh effi ci ency cool er.
Thi s cool er i s al so an oi l -to-cool ant type whi ch con-
si sts of pl ates mounted i n the radi ator outl et tank
and i s al so suppl i ed as opti onal equi pment.
NOTE: IF A VEHICLE WITH THE TRAILER TOWING
OPTION DOES NOT HAVE AN EXTERNAL AUXIL-
IARY TRANSMISSION COOLER, THAN IT IS
EQUIPPED WITH THE INTERNAL, HIGH-EFFICIENCY
COOLER.
COOLANT RESERVE/OVERFLOW SYSTEM
Thi s system works al ong wi th the radi ator pres-
sure cap. Thi s i s done by usi ng thermal expansi on
and contracti on of the cool ant to keep the cool ant
free of trapped ai r. I t provi des:
A vol ume for cool ant expansi on and contracti on.
A conveni ent and safe method for checki ng/ad-
justi ng cool ant l evel at atmospheri c pressure. Thi s i s
done wi thout removi ng the radi ator pressure cap.
Some reserve cool ant to the radi ator to cover
mi nor l eaks and evaporati on or boi l i ng l osses.
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
The cool ant reserve/overfl ow system has a radi ator
mounted pressuri zed cap, an overfl ow tube and a
pl asti c cool ant reserve/overfl ow tank (Fi g. 4) mounted
to the ri ght i nner fender.
Fig. 3 Water Pump Bypass Hose5.2/5.9LEngines
THREADED NUT FAN BLADE ASSEM- BLYPULLEYBOLTS
WATER
PUMP PUL-
LEY
WATER PUMP BYPASS HOSE CRANKSHAFT PULLEY THREADED SHAFT (WATER PUMP HUB) VISCOUS FAN DRIVE
Fig. 4 Coolant Reserve/Overflow TankTypical
COOLANT OVERFLOW HOSE COOLANT LEVEL SENSOR COOLANT RESERVE/OVER- FLOW TANK
ACCESSORY DRIVE BELT TENSION
Correct dri ve bel t tensi on i s requi red to ensure
opti mum performance of the bel t dri ven engi ne acces-
sori es. I f speci fi ed tensi on i s not mai ntai ned, bel t
sl i ppage may cause; engi ne overheati ng, l ack of
power steeri ng assi st, l oss of ai r condi ti oni ng capac-
i ty, reduced generator output rate, and greatl y
reduced bel t l i fe.
4.0L ENGINE
Bel t tensi on i s adjusted at the power steeri ng
pump bracket and i dl er pul l ey asseml y. There are di f-
ferent types of adjustment gauges for checki ng ei ther
a serpenti ne or a V-type bel t. Refer to the i nstruc-
ti ons suppl i ed wi th the gauge. Use the correct gauge
when checki ng bel t tensi on. Pl ace gauge i n the mi d-
dl e of the secti on of bel t bei ng tested (between two
pul l eys) to check tensi on. Do not al l ow the gauge (or
gauge adapter) to contact anythi ng but the bel t.
5.2/5.9L ENGINES
I t i s not necessary to adjust bel t tensi on on the 5.2/
5.9L engi nes. These engi nes are equi pped wi th an
automati c bel t tensi oner. The tensi oner mai ntai ns
correct bel t tensi on at al l ti mes. Due to use of thi s
bel t tensi oner, do not attempt to use a bel t tensi on
gauge on 5.2/5.9L engi nes.
ENGINE BLOCK HEATER
An opti onal engi ne bl ock heater (Fi g. 5) (Fi g. 6)i s
avai l abl e wi th for al l model s. The heater i s equi pped
wi th a power cord. The cord i s attached to an engi ne
compartment component wi th ti e-straps. The heater
warms the engi ne provi di ng easi er engi ne starti ng
and faster warm-up i n l ow temperatures. The heater
i s mounted i n a core hol e of the engi ne cyl i nder bl ock
i n pl ace of a freeze pl ug wi th the heati ng el ement
i mmersed i n engi ne cool ant. Connect power cord to a
grounded 110-120 vol t AC el ectri cal outl et wi th a
grounded, three wi re extensi on cord.
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
THERMOSTAT
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195F (90C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm up and overal l
temperature control .
An arrow, pl us the word UP i s stamped on the
front fl ange next to the ai r bl eed. The words TO
RAD are stamped on one arm of the thermostat.
They i ndi cate the proper i nstal l ed posi ti on.
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warmup ti me, unrel i -
abl e warmup performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
CAUTION: Do not operate an engine without a
thermostat, except for servicing or testing.
Fig. 5 Block Heater4.0L 6-Cyl. Engine
POWER CORD LOCA- TION BLOCK HEATER
Fig. 6 Block Heater5.2/5.9L V-8 Engines
LOWER ENGINE BLOCK POWERCORD BLOCKHEATER
The more common type of thermostat fai l ure, usu-
al l y found on hi gh mi l eage vehi cl es, i s a thermostat
fai l ed i n the shut posi ti on. The temperature gauge (i f
equi pped) wi l l gi ve an i ndi cati on of thi s condi ti on.
Dependi ng upon l ength of ti me that vehi cl e i s oper-
ated, pressure cap may vent. Thi s wi l l expel steam
and cool ant to cool ant reserve/overfl ow tank and to
surface bel ow vehi cl e. Refer to the Di agnosi s secti on
of thi s group.
COOLANT PERFORMANCE
ETHYLENE-GLYCOL MIXTURES
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon the cl i mate and vehi cl e oper-
ati ng condi ti ons. The recommended mi xture of 50/50
ethyl ene-gl ycol and water wi l l provi de protecti on
agai nst freezi ng to -37 deg. C (-35 deg. F). The anti -
freeze concentrati on must always be a mi ni mum of
44 percent, year-round i n al l cl i mates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maxi mum protecti on agai nst freezi ng i s provi ded
wi th a 68 percent anti freeze concentrati on, whi ch
prevents freezi ng down to -67.7 deg. C (-90 deg. F). A
hi gher percentage wi l l freeze at a warmer tempera-
ture. Al so, a hi gher percentage of anti freeze can
cause the engi ne to overheat because the speci fi c
heat of anti freeze i s l ower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used in
Chrysler Vehicles
Use of 100 percent ethyl ene-gl ycol wi l l cause for-
mati on of addi ti ve deposi ts i n the system, as the cor-
rosi on i nhi bi ti ve addi ti ves i n ethyl ene-gl ycol requi re
the presence of water to di ssol ve. The deposi ts act as
i nsul ati on, causi ng temperatures to ri se to as hi gh as
149 deg. C (300) deg. F). Thi s temperature i s hot
enough to mel t pl asti c and soften sol der. The
i ncreased temperature can resul t i n engi ne detona-
ti on. I n addi ti on, 100 percent ethyl ene-gl ycol freezes
at 22 deg. C (-8 deg. F ).
Propylene-glycol Formulations Should Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications. I ts overal l effec-
ti ve temperature range i s smal l er than that of ethyl -
ene-gl ycol . The freeze poi nt of 50/50 propyl ene-gl ycol
and water i s -32 deg. C (-26 deg. F). 5 deg. C hi gher
than ethyl ene-gl ycol s freeze poi nt. The boi l i ng poi nt
(protecti on agai nst summer boi l -over) of propyl ene-
gl ycol i s 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi ),
compared to 128 deg. C (263 deg. F) for ethyl ene-gl y-
col . Use of propyl ene-gl ycol can resul t i n boi l -over or
freeze-up i n Chrysl er vehi cl es, whi ch are desi gned for
ethyl ene-gl ycol . Propyl ene gl ycol al so has poorer heat
transfer characteri sti cs than ethyl ene gl ycol . Thi s
can i ncrease cyl i nder head temperatures under cer-
tai n condi ti ons.
Propylene-glycol/Ethylene-glycol Mixtures Should Not Be
Used in Chrysler Vehicles
Propyl ene-gl ycol /ethyl ene-gl ycol Mi xtures can
cause the destabi l i zati on of vari ous corrosi on i nhi bi -
tors, causi ng damage to the vari ous cool i ng system
components. Al so, once ethyl ene-gl ycol and propy-
l ene-gl ycol based cool ants are mi xed i n the vehi cl e,
conventi onal methods of determi ni ng freeze poi nt wi l l
not be accurate. Both the refracti ve i ndex and spe-
ci fi c gravi ty di ffer between ethyl ene gl ycol and propy-
l ene gl ycol .
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION-ADDITIVES
The presence of al umi num components i n the cool -
i ng system requi res stri ct corrosi on protecti on. Mai n-
tai n cool ant at speci fi ed l evel wi th a mi xture of
ethyl ene-gl ycol based anti freeze and water. Chrysl er
Corporati on recommends Mopar Anti freeze or equi v-
al ent. I f cool ant becomes contami nated or l ooses
col or, drai n and fl ush cool i ng system and fi l l wi th
correctl y mi xed sol uti on.
A 0.25 percent emul si fi abl e oi l i s added to the radi -
ator at the factory to prevent sol der corrosi on.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
RADIATOR PRESSURE CAP
Al l radi ators are equi pped wi th a pressure cap.
Thi s cap rel eases pressure at some poi nt wi thi n a
range of 97-to-124 kPa (14-to-18 psi ). The pressure
rel i ef poi nt (i n pounds) i s engraved on top of the cap
(Fi g. 7).
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap (Fi g. 7) contai ns a
spri ng-l oaded pressure rel i ef val ve. Thi s val ve opens
when system pressure reaches the rel ease range of
97-to-124 kPa (14-to-18 psi ).
A vent val ve i n the center of the cap al l ows a smal l
cool ant fl ow through the cap when cool ant i s bel ow
boi l i ng temperature. The val ve i s compl etel y cl osed
when boi l i ng poi nt i s reached. As the cool ant cool s, i t
contracts and creates a vacuum i n cool i ng system.
Thi s causes the vacuum val ve to open and cool ant i n
reserve/overfl ow tank to be drawn through connect-
i ng hose i nto radi ator. I f the vacuum val ve i s stuck
shut, radi ator hoses wi l l col l apse on cool -down.
A rubber gasket seal s the radi ator fi l l er neck. Thi s
i s done to mai ntai n vacuum duri ng cool ant cool -down
and to prevent l eakage when system i s under pres-
sure.
WATER PUMP
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t on al l engi nes.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary.
CAUTION: All 4.0L 6-cylinder engines are equipped
with a reverse (counterclockwise) rotating water
pump and thermal viscous fan drive assembly.
REVERSE is stamped or imprinted on the cover of
the viscous fan drive and inner side of the fan. The
letter R is stamped into the back of the water pump
impeller (Fig. 8). Engines from previous model
years, depending upon application, may have been
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump or vis-
cous fan drive will cause engine over heating.
A qui ck test to determi ne i f the pump i s worki ng i s
to check i f the heater warms properl y. A defecti ve
water pump wi l l not be abl e to ci rcul ate heated cool -
ant through the l ong heater hose to the heater core.
5.2/5.9L ENGINES: One of the heater hoses i s
connected to the water pump wi th a metal cool ant
return tube (Fi g. 9). A rubber o-ri ng forms a seal at
the water pump end of the tube.
COOLING SYSTEM HOSES
Rubber hoses route cool ant to and from the radi a-
tor, i ntake mani fol d and heater core.
The l ower radi ator hose i s spri ng-rei nforced to pre-
vent col l apse from water pump sucti on at moderate
and hi gh engi ne speeds.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 10). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
Fig. 7 Radiator Pressure CapTypical
TOP VIEWPRESSURE RATING CROSS-SECTIONAL VIEW FILLER NECK SEAL PRESSURE VALVE VACUUM VENT VALVE (SHOWN IN SEALING POSITION)
Fig. 8 Reverse Rotating Water Pump4.0L6-
Cylinder
FRONT VIEW ROTATION DIRECTION AS VIEWED BACK VIEW ROTATION DIRECTION AS VIEWED R STAMPED INTO IMPELLER
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 11). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
I nspect the hoses at regul ar i nterval s. Repl ace
hoses that are cracked, feel bri ttl e when squeezed, or
swel l excessi vel y when the system i s pressuri zed.
For al l vehi cl es: I n areas where speci fi c routi ng
cl amps are not provi ded, be sure that hoses are posi -
ti oned wi th suffi ci ent cl earance. Check cl earance
from exhaust mani fol ds and pi pe, fan bl ades, dri ve
bel ts and sway bars. I mproperl y posi ti oned hoses can
be damaged, resul ti ng i n cool ant l oss and engi ne
overheati ng.
Ordi nary worm gear type hose cl amps (when
equi pped) can be removed wi th a strai ght screw-
dri ver or a hex socket. To prevent damage to
hoses or clamps, the hose clamps should be
tightened to 4 Nm (34 in. lbs.) torque. Do not
over tighten hose clamps.
When performi ng a hose i nspecti on, i nspect the
radi ator l ower hose for proper posi ti on and condi ti on
of the i nternal spri ng.
VISCOUS FAN DRIVE
The thermal vi scous fan dri ve (Fi g. 12) (Fi g. 13)i s a
si l i cone-fl ui d-fi l l ed coupl i ng used to connect the fan
bl ades to the water pump shaft. The coupl i ng al l ows
the fan to be dri ven i n a normal manner. Thi s i s
done at l ow engi ne speeds whi l e l i mi ti ng the top
speed of the fan to a predetermi ned maxi mum l evel
at hi gher engi ne speeds.
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t (Fi g. 12)
(Fi g. 13). Thi s spri ng coi l reacts to the temperature
of the radi ator di scharge ai r. I t engages the vi scous
fan dri ve for hi gher fan speed i f the ai r temperature
from the radi ator ri ses above a certai n poi nt. Unti l
addi ti onal engi ne cool i ng i s necessary, the fan wi l l
remai n at a reduced rpm regardl ess of engi ne speed.
Onl y when suffi ci ent heat i s present, wi l l the vi s-
cous fan dri ve engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
Fig. 9 Coolant Return Tube5.2/5.9LV-8 Engines
MOUNTING BOLT COOLANT RETURN TUBE HEATERHOSE MOUNTING NUT WATER PUMP O-RING
Fig. 10 Hose Clamp ToolTypical
HOSE CLAMP TOOL 6094 HOSECLAMP
Fig. 11 Clamp Number/Letter Location
TYPICAL CONSTANT TENSION HOSE CLAMP TYPICAL HOSE CLAMP NUMBER/LETTER LOCATION
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
The underhood temperature i s above the engage-
ment poi nt for the vi scous dri ve coupl i ng. Thi s may
occur when ambi ent (outsi de ai r temperature) i s very
hi gh.
Engi ne l oads and temperatures are hi gh such as
when towi ng a trai l er.
Cool si l i cone fl ui d wi thi n the fan dri ve uni t i s
bei ng redi stri buted back to i ts normal di sengaged
(warm) posi ti on. Thi s can occur duri ng the fi rst 15
seconds to one mi nute after engi ne start-up on a col d
engi ne.
LEAKS
Vi scous fan dri ve operati on i s not affected by smal l
oi l stai ns near the dri ve beari ng. I f l eakage appears
excessi ve, repl ace the fan dri ve uni t.
ON-BOARD DIAGNOSTICS (OBD)
FOR CERTAIN COOLING SYSTEM
COMPONENTS
The powertrai n control modul e (PCM) has been
programmed to moni tor certai n cool i ng system com-
ponents:
NOTE: If the engine has remained cool for too long
a period, such as with a stuck open thermostat, a
Diagnostic Trouble Code (DTC) number 17 can be
observed at the malfunction indicator lamp. This
lamp is displayed on the instrument panel as the
CHECK ENGINE lamp (Fig. 14).
Fig. 12 Viscous Fan Drive4.0L EngineTypical
VISCOUS FAN DRIVE MOUNTING HUB THERMOSTATICSPRING
Fig. 13 Viscous Fan Drive5.2/5.9LEngines
Typical
VISCOUS FAN DRIVE THERMOSTATIC SPRING MOUNTING NUT TO WATER PUMP HUB
Fig. 14 Check Engine Lamp Location
CHECK ENGINE LAMP
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cate an actual probl em, a DTC i s
stored. The DTC wi l l be stored i n the PCM memory
for eventual di spl ay to the servi ce techni ci an. I f the
probl em i s repai red or ceases to exi st, the PCM can-
cel s the DTC after 51 engi ne starts.
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 temperature
and/or i nput vol tage to the PCM.
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 never i den-
ti fy the fai l ed component di rectl y.
I t i s possi bl e that a DTC for a moni tored ci rcui t
may not be entered i nto memory even though a mal -
functi on has occurred. Refer to On- Board Di agnos-
ti cs (OBD) i n Group 25, Emi ssi on Control Systems
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored Di agnosti c Troubl e Code (DTC) can be di s-
pl ayed by cycl i ng the i gni ti on key On-Off-On-Off-On
wi thi n three seconds and observi ng the mal functi on
i ndi cator l amp. Thi s l amp i s di spl ayed on the i nstru-
ment panel as the CHECK ENGI NE l amp (Fi g. 14).
They can al so be di spl ayed through the use of the
Di agnosti c Readout Box (DRB) scan tool . The DRB
connects to the data l i nk connector, l eft of the steer-
i ng col umn above the brake pedal (Fi g. 15). For oper-
ati on of the DRB, refer to the appropri ate Powertrai n
Di agnosti c Procedures servi ce manual .
EXAMPLES:
I f the l amp (Fi g. 14) fl ashes 1 ti me, pauses and
fl ashes 2 more ti mes, a fl ashi ng Di agnosti c Troubl e
Code (DTC) number 12 i s i ndi cated. I f thi s code i s
observed, i t i s i ndi cati ng that the battery has been
di sconnected wi thi n the l ast 50 key-on cycl es. I t
coul d al so i ndi cate that battery vol tage has been di s-
connected to the PCM. I n ei ther case, other DTCs
may have been erased.
I f the l amp fl ashes 1 ti me, pauses and fl ashes 7
more ti mes, a fl ashi ng Di agnosti c Troubl e Code
(DTC) number 17 i s i ndi cated.
After any stored DTC i nformati on has been
observed, the di spl ay wi l l end wi th a fl ashi ng DTC
number 55. Thi s wi l l i ndi cate the end of al l stored
i nformati on.
ERASING TROUBLE CODES
After the probl em has been repai red, use the DRB
scan tool to erase a DTC. Refer to the appropri ate
Powertrai n Di agnosti c Procedures servi ce manual for
operati on of the DRB scan tool .
DRB SCAN TOOL
For operati on of the DRB scan tool , refer to the
appropri ate Powertrai n Di agnosti c Procedures ser-
vi ce manual .
WATER PUMP TESTS
LOOSE IMPELLER
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Drai n the cool i ng system. Refer to Drai ni ng
Cool i ng System i n thi s group.
(2) Loosen the fan bel t. Refer to Bel t Servi ce i n the
Engi ne Accessory Dri ve Bel t secti on of thi s group.
(3) Di sconnect the l ower radi ator hose from the
water pump.
(4) Bend a sti ff wel di ng rod or si mi l ar devi ce as
shown i n (Fi g. 16). To prevent breakage of rod, mi n-
i mum thi ckness shoul d be 3/16 i nch (.187 i nches).
(5) Posi ti on the rod i n the water pump i nl et and
attempt to hol d the i mpel l er whi l e turni ng the fan
pul l ey. I f equi pped wi th a thermal vi scous fan dri ve,
rotate the water pump shaft wi th a wrench attached
to one of the fan pul l ey mounti ng nuts. I f the i mpel -
l er i s l oose and can be hel d wi th the rod whi l e the
fan bl ades are turni ng, the pump i s defecti ve. Do not
use excessi ve force when rotati ng pump shaft. I f the
i mpel l er turns, the pump i s OK.
(6) Connect the hose and i nstal l the cool ant, or
proceed wi th repai rs.
Fig. 15 Data Link Connector Location
HEADLAMPSWITCH DATA LINK CONNECTOR (LEFT SIDE OF COLUMN ABOVE BRAKE PEDAL)
INSPECTING FOR INLET RESTRICTIONS
I nadequate heater performance may be caused by
a metal casti ng restri cti on i n the water pump heater
hose i nl et.
cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
WARNING: DO NOT LOOSEN THE RADIATOR
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Drai n suffi ci ent cool ant from the radi ator to
decrease the l evel bel ow the water pump heater hose
i nl et.
(2) Remove the heater hose.
(3) I nspect the i nl et for metal casti ng fl ash or
other restri cti ons.
NOTE: Remove the pump from the engine before
removing restriction to prevent contamination of
the coolant with debris. Refer to Water Pump
Removal in this group.
THERMOSTAT
ON-BOARD DIAGNOSTICS
Al l model s are equi pped wi th On-Board Di agnos-
ti cs for certai n cool i ng system components. Refer to
On-Board Di agnosti cs (OBD) i n the Di agnosi s secti on
of thi s group for addi ti onal i nformati on. I f the pow-
ertrai n control modul e (PCM) detects l ow engi ne cool -
ant temperature, i t wi l l record a Di agnosti c Troubl e
Code (DTC) i n the PCM memory. The DTC number
for l ow cool ant temperature i s 17. Do not change a
thermostat for l ack of heat as i ndi cated by the
i nstrument panel gauge or heater performance
unl ess a DTC number 17 i s present. Refer to the
Di agnosi s secti on of thi s group for other probabl e
causes. For other DTC numbers, refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control Systems.
The DTC can al so be accessed through the DRB
scan tool . Refer to the appropri ate Powertrai n Di ag-
nosti c Procedures manual for di agnosti c i nformati on
and operati on of the DRB scan tool .
SERPENTINE DRIVE BELT DIAGNOSIS
When di agnosi ng serpenti ne dri ve bel ts, smal l
cracks that run across ri bbed surface of bel t from ri b
to ri b (Fi g. 17), are consi dered normal . These are not
a reason to repl ace bel t. However, cracks runni ng
al ong a ri b (not across) are not normal . Any bel t
wi th cracks runni ng al ong a ri b must be repl aced
(Fi g. 17). Al so repl ace bel t i f i t has excessi ve wear,
frayed cords or severe gl azi ng.
Refer to the Serpenti ne Dri ve Bel t Di agnosi s
charts for further bel t di agnosi s.
Fig. 16 Impeller TestTypical
IMPELLER 1 INCH 1 1/2 INCHES 3/16 INCH WELDING ROD
9 INCHES
Fig. 17 Serpentine Accessory Drive Belt
WearPatterns
NORMAL CRACKS BELT OK NOT NORMAL CRACKS RELACE BELT
SERPENTINE DRIVE BELT DIAGNOSIS4.0L 6-CYLINDER ENGINE
CONDITION POSSIBLE CAUSES POSSIBLE CAUSES
RIB CHUNKING (ONE OR MORE RIBS
HAS SEPARATED FROM BELT BODY)
1. Foreign objects imbedded in
pulley grooves.
1. Remove foreign objects from pulley
grooves. Replace belt.
2. Installation damage. 2. Replace belt.
RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).
2. Abrasive environment. 2. Clean pulley(s). Replace belt if
necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove
tips.
4. Replace pulley.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT CRACKING
(CRACKS BETWEEN TWO RIBS)
1. Belt has mistracked from pulley
groove.
1. Repace belt.
2. Pulley groove tip has worn away
rubber to tensile member.
2. Replace belt.
BELT SLIPS 1. Belt slipping because of
insufficient tension.
1. Replace automatic belt tensioner.
2. Belt or pulley subjected to
substance (belt dressing, oil ethylene
glycol) that has reduced friction.
2. Replace belt and clean pulleys.
3. Driven component bearing failure. 3. Replace faulty component bearing.
4. Belt glazed and hardened from
heat and excessive slippage.
4. Replace belt.
GROOVE JUMPING (BELT DOES NOT
MAINTAIN CORRECT POSITION ON
PULLEY)
1. Belt tension either too high or too
low.
1. Adjust belt tension.
2. Pulley(s) not within design
tolerance.
2. Replace pulley(s).
3. Foreign object(s) in grooves. 3. Remove foreign objectsfrom grooves.
4. Pulley misalignment. 4. Align component.
5. Belt cordline is broken. 5. Replace belt.
BELT BROKEN (NOTE: IDENTIFY AND
CORRECT PROBLEM BEFORE NEW
BELT IS INSTALLED)
1. Excessive tension. 1. Replace belt and adjust tension to
specification.
2. Tensile member damaged during
belt instalation.
2. Replace belt.
3. Severe misalignment. 3. Align pulley(s).
4. Bracket, pulley, or bearing failure. 4. Replace defective component and belt.
NOISE (OBJECTIONAL SQUEAL,
SQUEAK, OR RUMBLE IS HEARD OR
FELT WHILE DRIVE BELT IS IN
OPERATION)
1. Belt slippage. 1. Adjust belt.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt/pulley(s).
4. Belt-to-pulley mismatch. 4. Install correct belt.
5. Driven component induced
vibration
5.Locate defective driven component and
repair.
6. System resonant frequency
induced vibration.
6.Vary belt tension within specifications.
Replace belt.
TENSION SHEETING FABRIC FAILURE
(WOVEN FABRIC ON OUTSIDE,
CIRCUMFERENCE OF BELT HAS
CRACKED OR SEPERATED FROM
BODY OF BELT)
1. Tension sheeting contacting
stationary object.
1. Correct rubbing condition.
2. Excessive heat causing woven
fabric to age.
2. Replace belt.
3. Tension sheeting splice has
fractured.
3. Replace belt.
CORD EDGE FAILURE (TENSILE
MEMBER EXPOSED AT EDGES OF
BELT OR SEPERATED FROM BELT
BODY)
1. Excessive tension. 1. Adjust belt tension.
2. Belt contacting stationary object. 2. Correct as necessary.
3. Pulley(s) out of tolerance. 3. Replace pulley.
4. Insufficient adhesion between
tensile member and rubber matrix.
4. Replace belt and adjust tension to
specifications.
SERPENTINE DRIVE BELT DIAGNOSIS-5.2/5.9L 8-CYLINDER ENGINES
RIB CHUNKING (ONE OR MORE
RIBS HAS SEPARATED FROM
BELT BODY)
1. Foreign objects imbedded in pulley
grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage. 2. Replace belt.
RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).
2. Abrasive environment. 2. Clean pulley(s). Replace belt if
necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove tips. 4. Replace pulley.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT CRACKING
(CRACKS BETWEEN TWO RIBS)
1. Belt has mistracked from pulley
groove.
1. Repace belt.
2. Pulley groove tip has worn away
rubber to tensile member.
2. Replace belt.
BELT SLIPS 1. Belt slipping because of insufficient
tension.
1. Replace automatic belt
tensioner.
2. Incorrect belt. 2. Replace belt.
3. Belt or pulley subjected to
substance (belt dressing, oil ethylene
glycol) that has reduced friction.
3. Replace belt and clean pulleys.
4. Driven component bearing failure. 4. replace faulty component
bearing.
5. Belt glazed and hardened from heat
and excessive slippage.
5. Replace belt.
GROOVE JUMPING (BELT
DOES NOT MAINTAIN CORRECT
POSITION ON PULLEY)
1. Belt tension either too high or too
low.
1. Replace automatic belt
tensioner.
2. Incorrect belt. 2. Replace belt.
3. Pulley(s) not within design
tolerance.
3. Replace pulley(s).
4. Foreign object(s) in grooves. 4. Remove foreign objectsfrom
grooves.
5. Pulley misalignment. 5. Check and replace.
6. Belt cordline is broken. 6. Replace belt.
BELT BROKEN (NOTE: IDENTIFY
AND CORRECT PROBLEM
BEFORE NEW BELT IS
INSTALLED)
1. Excessive tension. 1. Replace belt and automatic belt
tensioner.
2. Incorect belt. 2. Replace belt.
3. Tensile member damaged during
belt instalation.
3. Replace belt.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.
NOISE (OBJECTIONAL SQUEAL,
SQUEAK, OR RUMBLE IS
HEARD OR FELT WHILE DRIVE
BELT IS IN OPERATION)
1. Belt slippage. 1. Replace belt or automatic belt
tensioner.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause.
(1) PROLONGED I DLE, VERY HI GH AMBI ENT
TEMPERATURE, SLI GHT TAI L WI ND AT I DLE,
SLOW TRAFFI C, TRAFFI C JAMS, HI GH SPEED,
OR STEEP GRADES:
Dri vi ng techni ques that avoi d overheati ng are:
I dl e wi th A/C off when temperature gauge i s at
end of normal range.
I ncreasi ng engi ne speed for more ai r fl ow i s rec-
ommended.
(2) TRAI LER TOWI NG:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
(3) AI R CONDI TI ONI NG; ADD-ON OR AFTER
MARKET:
A maxi mum cool i ng package shoul d have been
ordered wi th vehi cl e i f add-on or after market A/C i s
i nstal l ed. I f not, maxi mum cool i ng system compo-
nents shoul d be i nstal l ed for model i nvol ved per
manufacturers speci fi cati ons.
(4) RECENT SERVI CE OR ACCI DENT REPAI R:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
Engi ne adjustments (i ncorrect ti mi ng)
Sl i ppi ng engi ne accessory dri ve bel t(s)
Brakes (possi bl y draggi ng)
Changed parts (i ncorrect water pump rotati ng i n
wrong di recti on)
Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under-fi l l ed or ai r trapped i n system).
Rubber and foam ai r seal s not properl y i nstal l ed
to radi ator or A/C condenser after a repai r.
Upper and l ower porti ons of radi ator fan shroud
not ti ghtl y connected. Al l ai r must fl ow through the
radi ator.
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to Cooling System Diagnosis charts.
These charts are to be used as a qui ck-reference
onl y. Refer to the group text for i nformati on.
COOLING SYSTEM DIAGNOSIS
TEMPERATURE GAUGE READS LOW 1. Has a Diagnostic Trouble Code (DTC)
number 17 been set indicating a stuck open
engine thermostat.
1. Refer to On-Board Diagnostics in the
service manual text. Replace thermostat if
necessary. If a Diagnostic Trouble Code
(DTC) number 17 has not been set, the
problem may be with the temperature gauge.
2. Is the temperature gauge (if equipped)
connected to the temperature gauge coolant
sensor on the engine?
2. Check the engine temperature sensor
connector in the engine compartment. Refer
to Group 8E. Repair as necessary.
3. Is the temperature gauge (if equipped)
operating OK?
3. Check gauge operation. Refer to Group
8E. Repair as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with poor heater
performance.
4. Check coolant level in the coolant
reserve/overflow tank and the radiator.
Inspect system for leaks. Repair leaks as
necessary. Refer to the Coolant section of
the manual text for Warnings and precautions
before removing the radiator cap.
5. Improper operation of internal heater
doors or heater controls.
5. Inspect heater and repair as necessary.
Refer to Group 24, Heating and Air
Conditioning for procedures.
TEMPERATURE GAUGE READS HIGH OR
ENGINE COOLANT WARNING LAMP
ILLUMINATES. COOLANT MAY OR MAY
NOT BE LOST OR LEAKING FROM
COOLING SYSTEM
1. Trailer is being towed, a steep hill is being
climbed, vehicle is operated in slow moving
traffic, or engine is being idled with very high
ambient (outside) temperatures and the air
conditioning is on. Higher altitudes could
aggravate these conditions.
1. This may be a temporary condition and
repair is not necessary. Turn off the air
conditioning and attempt to drive the vehicle
without any of the previous conditions.
Observe the temperature gauge. The gauge
should return to the normal range. If the
gauge does not return to normal range,
determine the cause for overheating and
repair. Refer to POSSIBLE CAUSES
(numbers 2 through 18).
2. Is temperature gauge (if equipped)
reading correctly?
2. Check gauge. Refer to Group 8E. Repair
as necessary.
3. Is temperature warning lamp (if equipped)
illuminating unnecessarily?
3. Check warning lamp operation. Refer to
Group 8E. Repair as necessary.
4. Coolant low in coolant reserve/overflow
tank and radiator?
4. Check for coolant leaks and repair as
necessary. Refer to Testing Cooling System
for Leaks in this group.
5. Pressure cap not installed tightly. If cap is
loose, boiling point of coolant will be
lowered. Also refer to the following step 6.
5. Tighten cap.
6. Poor seals at radiator cap. 6. (a) Check condition of cap and cap seals.
Refer to Radiator Cap. Replace cap if
necessary.
(b) Check condition of radiator filler neck. If
neck is bent or damaged, replace radiator.
7. Coolant level low in radiator but not in
coolant reserve/overflow tank. This means
the radiator is not drawing coolant from the
coolant reserve/overflow tank as the engine
cools.
As the engine cools, a vacuum is formed in
the cooling system of the engine and
radiator. If radiator cap seals are defective,
or cooling system has leaks, a vacuum can
not be formed.
7. (a) Check condition of radiator cap and
cap seals. Refer to Radiator Cap in this
group. Replace cap if necessary.
(b) Check condition of radiator filler neck. If
neck is bent or damaged, replace radiator.
(c) Check the condition of the hose from the
radiator to the coolant tank. It should fit tight
at both ends without any kinks or tears.
Replace hose if necessary.
(d) Check coolant reserve/overflow tank and
tank hoses for blockage. Repair as
necessary
8. Freeze point of antifreeze not correct.
Mixture may be too rich.
8. Check antifreeze. Refer to Coolant section
of this group. Adjust antifreeze-to-water ratio
as required.
TEMPERATURE GAUGE READS HIGH OR
ENGINE COOLANT WARNING LAMP
ILLUMINATES. COOLANT MAY OR MAY
NOT BE LOST OR LEAKING FROM
COOLING SYSTEM
9. Coolant not flowing through system. 9. Check for coolant flow at radiator filler
neck with some coolant removed, engine
warm and thermostat open. Coolant should
be observed flowing through radiator. If flow
is not observed, determine reason for lack of
flow and repair as necessary.
10. Radiator or A/C condenser fins are dirty
or clogged.
10. Clean insects or debris. Refer to Radiator
Cleaning in this group.
11. Radiator core is corroded or plugged. 11. Have radiator re-cored or replaced.
12. Fuel or ignition system problems. 12. Refer to Fuel and Ignition System groups
for diagnosis. Also refer to the appropriate
Powertrain Diagnostic Procedures service
manual for operation of the DRB scan tool.
13. Dragging brakes. 13. Check and correct as necessary. Refer to
Group 5, Brakes in the manual text.
14. Bug screen is being used reducing
airflow.
14. Remove bug screen.
15. Thermostat partially or completely shut.
This is more prevalent of high mileage
vehicles.
15. Check thermostat operation and replace
as necessary. Refer to Thermostats in this
group.
16. Thermal viscous fan drive not operating
properly.
16. Check fan drive operation and replace if
necessary. Refer to Viscous Fan Drive in this
group.
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket leaks.
Refer to Testing Cooling System for Leaks in
this group. For repair, refer to Group 9,
Engines.
18. Heater core leaking. 18. Check heater core for leaks. Refer to
Group 24, Heating and Air Conditioning.
Repair as necessary.
TEMPERATURE GAUGE READING IS
INCONSISTENT (FLUCTUATES, CYCLES
OR IS ERRATIC)
1. During cold weather operation, with the
heater blower in the high position, the gauge
reading may drop slightly.
1. A normal condition. No correction is
necessary.
2. Temperature gauge or engine mounted
gauge sensor defective or shorted. Also,
corroded or loose wiring in the circuit.
2. Check operation of gauge and repair if
necessary. Refer to Group 8E, Instrument
Panel and Gauges.
3. Gauge reading rises when vehicle is
brought to a stop after heavy use (engine
still running).
necessary. Gauge reading should return to
normal range after vehicle is driven.
4. Gauge reading high after restarting a
warmed-up (hot) engine.
necessary. The gauge should return to
normal range after a few minutes of engine
operation.
5. Coolant level low in radiator (air will build
up in the cooling system causing the
thermostat to open late).
5. Check and correct coolant leaks. Refer to
Testing Cooling System for Leaks in this
group.
6. Cylinder head gasket leaking allowing
exhaust gas to enter cooling system causing
thermostat to open late.
6. (a) Check for cylinder head gasket leaks
with a commercially available Block Leak
Tester. Repair as necessary.
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from exhaust
system. Repair as necessary.
7. Water pump impeller loose on shaft. 7. Check water pump and replace as
necessary. Refer to Water Pumps in this
group.
8. Loose accessory drive belt (water pump
slipping).
8. Refer to Engine Accessory Drive Belts in
this group. Check and correct as necessary.
. Air leak on the suction side of water pump
allows air to build up in cooling system
causing thermostat to open late.
9. Locate leak and repair as necessary.
PRESSURE CAP IS BLOWING OFF STEAM
AND/OR COOLANT TO COOLANT TANK.
TEMPERATURE GAUGE READING MAY BE
ABOVE NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE HIGH IN
COOLANT RESERVE/OVERFLOW TANK
1. Pressure relief valve in radiator cap is
defective.
1. Check condition of radiator cap and cap
seals. Refer to Radiator Caps in this group.
Replace cap as necessary.
COOLANT LOSS TO THE GROUND
WITHOUT PRESSURE CAP BLOWOFF.
GAUGE IS READING HIGH OR HOT
1. Coolant leaks in radiator, cooling system
hoses, water pump or engine.
1. Pressure test and repair as necessary.
Refer to Testing Cooling System for Leaks in
this group.
DETONATION OR PRE-IGNITION (NOT
CAUSED BY IGNITION SYSTEM). GAUGE
MAY OR MAY NOT BE READING HIGH
1. Engine overheating. 1. Check reason for overheating and repair
as necessary.
2. Freeze point of antifreeze not correct.
Mixture is too rich or too lean.
2. Check antifreeze. Refer to the Coolant
section of this group. Adjust antifreeze-to-
water ratio as required.
HOSE OR HOSES COLLAPSED WHEN
ENGINE IS COOLING
1. Vacuum created in cooling system on
engine cool-down is not being relieved
through coolant reserve/overflow system.
1. (a) Radiator cap relief valve stuck. Refer to
Radiator Cap in this group. Replace if
necessary.
(b) Hose between coolant reserve/overflow
tank and radiator is kinked. Repair as
necessary.
(c) Vent at coolant reserve/overflow tank is
plugged. Clean vent and repair as necessary.
(d) Reserve/overflow tank is interally blocked
or plugged. Check for blockage and repair as
necessary.
NOISY FAN 1. Fan blades loose. 1. Replace fan blade assembly. Refer to
Cooling System Fans in this group.
2. Fan blades striking a surrounding object. 2. Locate point of fan blade contact and
repair as necessary.
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or clean debris
or insects from radiator or A/C condenser.
4. Thermal viscous fan drive has defective
bearing.
4. Replace fan drive. Bearing is not
serviceable. Refer to Viscous Fan Drive in
this group.
5. A certain amount of fan noise (roaring)
may be evident on models equipped with a
thermal viscous fan drive. Some of this noise
is normal.
5. Refer to Viscous Fan Drive in this group
for an explanation of normal fan noise.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING SYSTEM
SUSPECTED)
1. Radiator and/or A/C condenser is
restricted, obstructed or dirty (insects, leaves
etc.)
1. Remove restriction and/or clean as
necessary. Refer to Radiator Cleaning in this
group.
2. Thermal viscous fan drive is free-
wheeling.
2. Refer to Viscous Fan Drive for diagnosis.
3. Engine is overheating (heat may be
transferred from radiator to A/C condenser.
High underhood temperatures due to engine
overheating may also transfer heat to A/C
components).
3. Correct overheating condition. Refer to text
in Group 7, Cooling.
. Some models with certain engines are
equipped with air seals at the radiator and/or
A/C condenser. If these seals are missing or
damaged, not enough air flow will be pulled
through the radiator and A/C condenser.
4. Check for missing or damaged air seals
and repair as necessary.
INADEQUATE HEATER PERFORMANCE.
THERMOSTAT FAILED IN OPEN POSITION
1. Has a diagnostic trouble code (DTC)
number 17 been set?
1. Refer to On-Board Diagnostics in the
manual text and replace thermostat if
necessary.
2. Coolant level low. 2. Refer to Testing Cooling System for Leaks
in the manual text. Repair as necessary.
3. Obstructions in heater hose fittings at
engine.
3. Remove heater hoses at both ends and
check for obstructions. Repair as necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Some models with certain engines are
equipped with a water control valve located
on one of the heater hoses. This valve
maybe defective.
5. Refer to Group 24, Heating and Air
Conditioning for diagnosis. Repair as
necessary.
6. Water pump is not pumping water to
heater core. When the engine is fully
warmed up, both heater hoses should be hot
to the touch. If only one of the hoses is hot,
the water pump may not be operating
correctly. The accessory drive belt may also
be slipping causing poor water pump
operation.
6. Refer to Water Pumps in this group.
Repair as necessary. If a slipping belt is
detected, refer to Engine Accessory Drive
Belts in this group. Repair as necessary.
HEAT ODOR 1. Various heat shields are used at certain
drive line components. One or more of these
shields may be missing.
1. Locate missing shields and replace or
repair as necessary.
2. Is temperature gauge reading above the
normal range?
2. Refer to the previous Temperature Gauge
Reads High in these Diagnosis Charts.
3. Is cooling fan operating correctly. 3. Refer to Cooling System Fan in this group
for diagnosis. Repair as necessary
4. Has undercoating been applied to any
unnecessary component.
4. Clean undercoating as necessary.
5. Engine may be running rich causing the
catalytic converter to overheat.
5. Refer to the DRB scan tool and the
appropriate Powertrain Diagnostic
Procedures service manual. Repair as
necessary.
POOR DRIVEABILITY (THERMOSTAT
POSSIBLY STUCK OPEN). GAUGE MAY BE
READING LOW
1. For proper driveability, good vehicle
emissions and for preventing build-up of
engine oil sludge, the thermostat must be
operating properly. Has a diagnostic trouble
code (DTC) number 17 been set?
1. Refer to On-Board Diagnostics in this
group. DTCs may also be checked using the
DRB scan tool. Refer to the proper
Powertrain Diagnostics Procedures service
manual for checking the thermostat using the
DRB scan tool. Replace thermostat if
necessary.
STEAM IS COMING FROM FRONT OF
VEHICLE NEAR GRILL AREA WHEN
WEATHER IS WET, ENGINE IS WARMED
UP AND RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. During wet weather, moisture (snow, ice
or rain condensation) on the radiator will
evaporate when the thermostat opens. This
opening allows heated water into the
radiator. When the moisture contacts the hot
radiator, steam may be emitted. This usually
occurs in cold weather with no fan or airflow
to blow it away.
1. Occasional steam emitting from this area
is normal. No repair is necessary.
COOLANT COLOR 1. Coolant color is not necessarily an
indication of adequate corrosion or
temperature protection. Do not rely on
coolant color for determining condition of
coolant.
1. Refer to Coolant in this group for
antifreeze tests. Adjust antifreeze-to-water
ratio as necessary.
COOLANT LEVEL CHANGES IN COOLANT
RESERVE/OVERFLOW TANK.
TEMPERATURE GAUGE IS IN NORMAL
RANGE
1. Level changes are to be expected as
coolant volume fluctuates with engine
temperature. If the level in the tank was
between the FULL and ADD marks at normal
engine operating temperature, the level
should return to within that range after
operation at elevated temperatures.
1. A normal condition. No repair is necessary.
RADIATOR COOLANT FLOW CHECK
The fol l owi ng procedure wi l l determi ne i f cool ant i s
fl owi ng through the cool i ng system.
I f engi ne i s col d, i dl e engi ne unti l normal operati ng
temperature i s reached. Then feel the upper radi ator
hose. I f hose i s hot, the thermostat i s open and water
i s ci rcul ati ng through cool i ng system.
TESTING COOLING SYSTEM FOR LEAKS
ULTRAVIOLET LIGHT METHOD
Al l Jeep model s have a l eak detecti on addi ti ve
added to the cool i ng system before they l eave the fac-
tory. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). I f the factory ori gi nal cool ant has
been drai ned, pour one ounce of addi ti ve i nto the
cool i ng system. The addi ti ve i s avai l abl e through the
parts department. Pl ace the heater control uni t i n
HEAT posi ti on. Start and operate the engi ne unti l
the radi ator upper hose i s warm to the touch. Ai m
the commerci al l y avai l abl e bl ack l i ght tool at the
components to be checked. I f l eaks are present, the
bl ack l i ght wi l l cause the addi ti ve to gl ow a bri ght
green col or.
The bl ack l i ght can be used al ong wi th a pressure
tester to determi ne i f any external l eaks exi st (Fi g.
18).
PRESSURE TESTER METHOD
The engi ne shoul d be at the normal operati ng tem-
perature. Recheck the system col d i f the cause of
cool ant l oss i s not l ocated duri ng warm engi ne exam-
i nati on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Careful l y remove the radi ator pressure cap from
the fi l l er neck and check the cool ant l evel . Push
down on the cap to di sengage i t from the stop tabs.
Wi pe the i nner part of the fi l l er neck and exami ne
the l ower i nsi de seal i ng seat for ni cks, cracks, pai nt,
di rt and sol der resi due. I nspect the reserve/overfl ow
tank tube for i nternal obstructi ons. I nsert a wi re
through the tube to be sure i t i s not obstructed.
I nspect the cams on the outsi de part of the fi l l er
neck. I f the cams are bent, seati ng of pressure cap
val ve and tester seal wi l l be affected. Repl ace cap i f
cams are bent.
Attach pressure tester 7700 (or an equi val ent) to
the radi ator fi l l er neck (Fi g. 19).
Operate the tester pump to appl y 124 kPa (18 psi )
pressure to the system. I f the hoses enl arge exces-
si vel y or bul ge whi l e testi ng, repl ace as necessary.
Observe the gauge poi nter and determi ne the condi -
ti on of the cool i ng system accordi ng to the fol l owi ng
cri teri a:
Hol ds Steady: I f the poi nter remai ns steady for
two mi nutes, there are no seri ous cool ant l eaks i n
the system. However, there coul d be an i nternal l eak
that does not appear wi th normal system test pres-
sure. I nspect for i nteri or l eakage or do the I nternal
Leakage Test. Do thi s i f i t i s certai n that cool ant i s
bei ng l ost and no l eaks can be detected.
Drops Sl owl y: Shows a smal l l eak or seepage i s
occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect the radi ator,
hoses, gasket edges and heater. Seal any smal l l eak
hol es wi th a Seal er Lubri cant or equi val ent. Repai r
l eak hol es and rei nspect the system wi th pressure
appl i ed.
Drops Qui ckl y: Shows that a seri ous l eakage i s
occurri ng. Exami ne the system for seri ous external
Fig. 18 Leak Detection Using Black LightTypical
TYPICAL BLACK
LIGHT TOOL
Fig. 19 Pressurizing SystemTypical
TYPICAL COOLING SYS- TEM PRESSURE TESTER
l eakage. I f no l eaks are vi si bl e, i nspect for i nternal
l eakage. Large radi ator l eak hol es shoul d be repai red
by a reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove the oi l pan drai n pl ug and drai n a smal l
amount of engi ne oi l . Cool ant, bei ng heavi er, wi l l
drai n fi rst, or operate engi ne to churn oi l , then exam-
i ne di psti ck for water gl obul es. I nspect the transmi s-
si on di psti ck for water gl obul es. I nspect the
transmi ssi on fl ui d cool er for l eakage. Operate the
engi ne wi thout the pressure cap on the radi ator unti l
thermostat opens.
Attach a Pressure Tester to the fi l l er neck. I f pres-
sure bui l ds up qui ckl y, a l eak exi sts as resul t of a
faul ty cyl i nder head gasket or crack i n the engi ne.
Repai r as necessary.
WARNING: DO NOT ALLOW PRESSURE TO
EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.
I f there i s no i mmedi ate pressure i ncrease, pump
the Pressure Tester unti l the i ndi cated pressure i s
wi thi n the system range. Vi brati on of the gauge
poi nter i ndi cates compressi on or combusti on l eakage
i nto the cool i ng system.
WARNING: DO NOT DISCONNECT THE SPARK
PLUG WIRES WHILE THE ENGINE IS OPERATING.
CAUTION: Do not operate the engine with a spark
plug shorted for more than a minute. The catalytic
converter may be damaged.
I sol ate the compressi on l eak by shorti ng each
spark pl ug to the cyl i nder bl ock. The gauge poi nter
shoul d stop or decrease vi brati on when spark pl ug
for l eaki ng cyl i nder i s shorted. Thi s happens because
of the absence of combusti on pressure.
COMBUSTION LEAKAGE TEST (WITHOUT
PRESSURE TESTER)
DO NOT WASTE reusabl 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.
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow for thermostat
removal . Refer to Thermostat Repl acement. Di scon-
nect the water pump dri ve bel t.
Di sconnect the upper radi ator hose from the ther-
mostat housi ng. Remove the housi ng and thermostat.
I nstal l the thermostat housi ng.
Add cool ant to the radi ator to bri ng the l evel to
wi thi n 6.3 mm (1/4 i n) of the top of the thermostat
housi ng.
CAUTION: Avoid overheating. Do not operate the
engine for an excessive period of time. Open the
draincock immediately after the test to eliminate
boil over of coolant.
Start the engi ne and accel erate rapi dl y three ti mes
(to approxi matel y 3000 rpm) whi l e observi ng the
cool ant. I f i nternal engi ne combusti on gases are l eak-
i ng i nto the cool i ng system, bubbl es wi l l appear i n
the cool ant. I f bubbl es do not appear, there i s no
i nternal combusti on gas l eakage.
VISCOUS FAN DRIVE
TESTING
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18 to
105C (0 to 220 F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght (ti mi ng l i ght i s to be used as a strobe
l i ght).
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
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.
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 88 C (190 F).
Fan dri ve engagement shoul d have started to occur
at between 74 to 82 C (165 to 180 F). Engage-
ment i s di sti ngui shabl e by a defi ni te increase i n fan
fl ow noi se (roari ng). The ti mi ng l i ght al so wi l l i ndi -
cate an i ncrease i n the speed of the fan.
(7) When the ai r temperature reaches 88 C (190
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 57 to
79 C (135 to 175 F). A defi ni te decrease of fan
fl ow noi se (roari ng) shoul d be noti ced. I f not, repl ace
the defecti ve vi scous fan dri ve uni t.
RADIATOR CAP-TO-FILLER NECK SEAL
PRESSURE RELIEF CHECK
Wi th radi ator cap i nstal l ed on fi l l er neck, remove
cool ant reserve/overfl ow tank hose from ni ppl e on
fi l l er neck. Connect a hand operated vacuum pump
to ni ppl e. Operate pump unti l a readi ng of 47 to 61
kPa (14 to 18 i n. Hg) appears on gauge. I f the read-
i ng stays steady, or drops sl i ghtl y and then remai ns
steady, the pressure val ve seal i s good. Repl ace radi -
ator cap i f readi ng does not hol d.
WARNING: THE WARNING WORDS DO NOT
OPEN HOT ON THE RADIATOR PRESSURE CAP
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT AND/OR UNDER PRESSURE.
There i s no need to remove the radi ator cap
except for the fol l owi ng purposes:
To check and adjust anti freeze freeze poi nt.
To refi l l system wi th new anti freeze.
For conducti ng servi ce procedures.
When checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE
REMOVING RADIATOR CAP. WITH A RAG,
SQUEEZE RADIATOR UPPER HOSE TO CHECK IF
SYSTEM IS UNDER PRESSURE. PLACE A RAG
OVER THE CAP AND WITHOUT PUSHING DOWN,
ROTATE CAP COUNTER-CLOCKWISE TO THE
FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH
OVERFLOW HOSE INTO COOLANT RESERVE/
OVERFLOW TANK. SQUEEZE RADIATOR UPPER
HOSE TO DETERMINE WHEN PRESSURE HAS
BEEN RELEASED. WHEN COOLANT AND STEAM
STOP BEING PUSHED INTO TANK AND SYSTEM
PRESSURE DROPS, REMOVE RADIATOR CAP
COMPLETELY.
PRESSURE TESTING RADIATOR CAP
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l the cap on pressure tester (tool 7700 or
an equi val ent) (Fi g. 20).
Operate the tester pump and observe the gauge
poi nter at i ts hi ghest poi nt. The cap rel ease pressure
shoul d be 97 to 124 kPa (14 to 18 psi ). The cap i s
sati sfactory when the pressure hol ds steady. I t i s al so
good i f i t hol ds pressure wi thi n the 97 to 124 kPa (14
to 18 psi ) range for 30 seconds or more. I f the poi nter
drops qui ckl y, repl ace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
Fig. 20 Pressure Testing Radiator PressureCap
Typical
PRESSURECAP TYPICAL COOLING SYSTEM PRESSURE TESTER
LOW COOLANT LEVEL-AERATION
I f the cool ant l evel i n radi ator drops bel ow top of
radi ator core tubes, ai r wi l l enter cool i ng system.
Low cool ant l evel can cause thermostat pel l et to be
suspended i n ai r i nstead of cool ant. Thi s wi l l cause
thermostat to open l ater, whi ch i n turn causes hi gher
cool ant temperature. Ai r trapped i n cool i ng system
al so reduces amount of cool ant ci rcul ati ng i n heater
core resul ti ng i n l ow heat output.
DEAERATION
As the engi ne operates, any ai r trapped i n cool i ng
system gathers under the radi ator cap. The next ti me
the engi ne i s operated, thermal expansi on of cool ant
wi l l push any trapped ai r past radi ator cap i nto the
cool ant reserve/overfl ow tank. Here i t escapes to the
atmosphere i nto the tank. When the engi ne cool s
down the cool ant, i t wi l l be drawn from the reserve/
overfl ow tank i nto the radi ator to repl ace any
removed ai r.
SERVICE PROCEDURES
ROUTINE COOLANT LEVEL CHECK
NOTE: Do not remove radiator cap for routine
coolant level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
The cool ant reserve/overfl ow system provi des a
qui ck vi sual method for determi ni ng cool ant l evel
wi thout removi ng radi ator pressure cap. Wi th engi ne
i dl i ng and at normal operati ng temperature, observe
cool ant l evel i n reserve/overfl ow tank. The cool ant
l evel shoul d be between ADD and FULL marks.
ADDING ADDITIONAL COOLANT
Do not remove radiator cap to add coolant to
system. When addi ng cool ant to mai ntai n correct
l evel , do so at cool ant reserve/overfl ow tank. Use a
50/50 mi xture of ethyl ene-gl ycol anti freeze and l ow
mi neral content water. Remove radi ator cap onl y for
testi ng or when refi l l i ng system after servi ce. Remov-
i ng cap unnecessari l y can cause l oss of cool ant and
al l ow ai r to enter system, whi ch produces corrosi on.
COOLANT LEVEL CHECK SERVICE
The cool i ng system i s cl osed and desi gned to mai n-
tai n cool ant l evel to top of radi ator.
WARNING: DO NOT OPEN RADIATOR DRAINCOCK
WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
AND COOLING SYSTEM IS UNDER PRESSURE.
When vehi cl e servi ci ng requi res a cool ant l evel
check i n radi ator, drai n several ounces of cool ant
from radi ator drai n cock. Do thi s whi l e observi ng
cool ant reserve/overfl ow system tank. The cool ant
l evel i n reserve/overfl ow tank shoul d drop sl i ghtl y. I f
not, i nspect for a l eak between radi ator and cool ant
reserve/overfl ow system connecti on. Remove radi ator
cap. The cool ant l evel shoul d be to top of radi ator. I f
not and i f cool ant l evel i n reserve/overfl ow tank i s at
ADD mark, check for:
An ai r l eak i n cool ant reserve/overfl ow tank or
i ts hose
An ai r l eak i n radi ator fi l l er neck
Leak i n pressure cap seal to radi ator fi l l er neck
DRAINING AND FILLING COOLING SYSTEM
DRAINING COOLING SYSTEM
DRAINCOCK WITH SYSTEM HOT AND UNDER
CAN OCCUR.
reuse.
DRAINING ENTIRE SYSTEM
Use thi s procedure i f the enti re cool i ng system i s to
be drai ned, such as for engi ne removal .
(1) DO NOT remove radi ator cap fi rst. Wi th engi ne
col d, rai se vehi cl e on a hoi st and l ocate radi ator
drai ncock.
4.0L 6-cyl . Engi ne: Radi ator drai ncock i s l ocated
on the ri ght/l ower si de of radi ator faci ng to rear of
vehi cl e.
5.2/5.9L V-8 Engi nes: Radi ator drai ncock i s
l ocated on the l eft/l ower si de of radi ator faci ng to
rear of vehi cl e.
(2) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner. Open drai ncock
and drai n cool ant from radi ator. Thi s wi l l empty the
cool ant reserve/overfl ow tank. The cool ant does not
have to be removed from the tank unl ess the system
i s bei ng refi l l ed wi th a fresh mi xture. When tank i s
empty, remove radi ator cap and conti nue drai ni ng
cool i ng system.
To drai n the 4.0L 6-cyl i nder engi ne of cool ant,
remove the cyl i nder bl ock drai n pl ug l ocated on the
si de of cyl i nder bl ock (Fi g. 21).
To drai n the 5.2/5.9L V-8 engi nes of cool ant,
remove the cyl i nder bl ock drai n pl ugs l ocated on the
si des of cyl i nder bl ock above the oi l pan rai l (Fi g. 22).
PARTIAL DRAINING
Use thi s procedure i f the cool ant i s to be parti al l y
drai ned, such as for engi ne thermostat removal .
(1) Wi th engi ne col d, sl owl y remove the radi ator
cap. Rai se vehi cl e on a hoi st and l ocate radi ator
drai ncock.
4.0L Engi ne: Radi ator drai ncock i s l ocated on
the ri ght/l ower si de of radi ator faci ng to rear of vehi -
cl e.
5.2/5.9L Engi nes: Radi ator drai ncock i s l ocated
on the l eft/l ower si de of radi ator faci ng to rear of
vehi cl e.
(2) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner.
(3) Open drai ncock and drai n desi red amount of
cool ant from radi ator.
REFILLING COOLING SYSTEM
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s) (i f removed).
(2) Fi l l system usi ng a 50/50 mi xture of ethyl ene-
gl ycol ani freeze and l ow mi neral conent water. Fi l l
radi ator to top and i nstal l radi ator cap. Add suffi -
ci ent cool ant to the reserve/overfl ow tank to rai se
l evel to FULL mark.
(3) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th radi ator cap i n pl ace.
(4) After engi ne has reached normal operati ng
temperature, shut engi ne off and al l ow i t to cool .
When engi ne i s cool i ng down, cool ant wi l l be drawn
i nto the radi ator from the reserve/overfl ow tank.
(5) Add cool ant to reserve/overfl ow tank as neces-
sary. Only add coolant to the reserve/overflow
tank when the engine is cold. Coolant level in a
warm engine will be higher due to thermal
expansion. To purge the cool i ng system of al l ai r,
thi s heat up/cool down cycl e (addi ng cool ant to col d
engi ne) must be performed three ti mes. Add neces-
sary cool ant to rai se tank l evel to the FULL mark
after each cool down peri od.
COOLING SYSTEM CLEANING/REVERSE FLUSHING
CAUTION: The cooling system normally operates
at 97 to 124 kPa (14 to 18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
CLEANING
Drai n cool i ng system and refi l l wi th water. Run
engi ne wi th radi ator cap i nstal l ed unti l upper radi a-
tor hose i s hot. Stop engi ne and drai n water from
system. I f water i s di rty, fi l l system wi th water, run
engi ne and drai n system. Repeat unti l water drai ns
cl ean.
REVERSE FLUSHING
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
at 97 to 124 kPa (14 to 18 psi) pressure. Exceeding
Al l ow the radi ator to fi l l wi th water. When radi ator
i s fi l l ed, appl y ai r i n short bl asts al l owi ng radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
Fig. 21 Drain Plug4.0L 6-CylinderEngine
COOLANT TEMPERATURE SENSOR BLOCK DRAIN PLUG
Fig. 22 Drain Plugs5.2/5.9L V-8 Engines
BLOCK DRAIN
PLUG
cool i ng tube passages. For more i nformati on, refer to
operati ng i nstructi ons suppl i ed wi th fl ushi ng equi p-
ment. Have radi ator cl eaned more extensi vel y by a
radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system. Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
Connect the water suppl y hose and ai r suppl y hose
to the fl ushi ng gun. Al l ow the engi ne to fi l l wi th
water. When the engi ne i s fi l l ed, appl y ai r i n short
bl asts, al l owi ng the system to fi l l between ai r bl asts.
Conti nue unti l cl ean water fl ows through the l ead
away hose. For more i nformati on, refer to operati ng
i nstructi ons suppl i ed wi th fl ushi ng equi pment.
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng and i nstal l thermostat. I nstal l the ther-
mostat housi ng wi th a repl acement gasket. Refer to
Thermostat Repl acement. Connect the radi ator
hoses. Refi l l the cool i ng system wi th the correct anti -
freeze/water mi xture.
CHEMICAL CLEANING
I n some i nstances, use a radi ator cl eaner (Mopar
Radi ator Kl een or equi val ent) before fl ushi ng. Thi s
wi l l soften scal e and other deposi ts and ai d the fl ush-
i ng operati on.
CAUTION: Be sure instructions on the container
are followed.
EXTERNAL TRANSMISSION OIL COOLER
AUXILIARY
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Remove the gri l l . Refer to Group 23, Body.
(3) Remove the bumper fasci a. Refer to Group 23,
Body.
(4) Remove the gri l l openi ng rei nforcement panel .
Refer to Group 23, Body.
(5) Remove two bracket bol ts and three brace bol ts
(Fi g. 23).
(6) Remove the retai ni ng cl i p from the cool er l i nes
(Fi g. 23).
(7) Pl ace a drai n pan under the cool er.
(8) Di sconnect the upper hose cl amp at cool er l i ne
(Fi g. 24). Separate the l i ne from the rubber hose.
(9) Posi ti on the cool er to gai n access to l ower hose.
The cool er l i nes are routed through a rubber seal
l ocated on the si de of radi ator. Be careful not to cut
or tear thi s seal when posi ti oni ng cool er for l ower
hose removal .
(10) Remove l ower hose cl amp and hose from
cool er.
(11) Remove cool er from vehi cl e.
Fig. 23 Oil Cooler Mounting BracketsTypical
BRACE BOLTS OIL COOLER BRACE CLIP FRONT LOWER CROSSMEM- BER BRACKET BOLTS
Fig. 24 Oil Cooler HosesTypical
RUBBER HOSE HOSE CLAMPS RUBBER HOSE HOSE CLAMPS
INSTALLATION
(1) Posi ti on cool er to vehi cl e.
(2) I nstal l l ower hose and hose cl amp to cool er.
Hose cl amp screws must be faci ng towards rear of
vehi cl e. Ti ghten cl amp to 2 Nm (18 i n. l bs.) torque.
(3) I nstal l upper hose and hose cl amp at cool er.
Hose cl amp screws must be faci ng towards rear of
vehi cl e. Ti ghten cl amp to 2 Nm (18 i n. l bs.) torque.
(4) I nstal l brace and mounti ng bracket bol ts (Fi g.
23).
(5) Connect negati ve battery cabl e to battery.
(6) Add necessary transmi ssi on fl ui d. Refer to
Group 21, Transmi ssi ons. Start engi ne and check for
l eaks.
(7) I nstal l gri l l openi ng rei nforcement panel ,
bumper fasci a and gri l l . Refer to Group 23, Body.
WATER PUMP 4. 0L ENGINE
CAUTION: If the water pump is replaced because
of mechanical damage, the fan blades and viscous
fan drive should also be inspected. These compo-
nents could have been damaged due to excessive
vibration.
REMOVAL
The water pump can be removed wi thout di scharg-
i ng the ai r condi ti oni ng system (i f equi pped).
CAUTION: The 4.0L engine has a reverse (counter-
clockwise) rotating water pump. The letter R is
stamped into the back of the water pump impeller
(Fig. 25) to identify. Engines from previous model
years, depending upon application, may be
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump will
cause engine over heating.
The water pump i mpel l er i s pressed on the rear of
the pump shaft and beari ng assembl y. The water
pump i s servi ced onl y as a compl ete assembl y.
WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
i s cl ean, drai n cool ant i nto a cl ean contai ner for
reuse.
(2) Drai n the cool i ng system.
(3) Vehicles with 4.0L 6-cylinder engine
equipped with A/C or heavy duty cooling sys-
tem:
(4) Loosen (but do not remove at thi s ti me) the
four water pump pul l ey-to-water pump hub mounti ng
bol ts (Fi g. 26).
(5) Vehicles with 4.0L 6-cylinder engine with-
out A/C or heavy duty cooling system:
(6) Loosen (but do not remove at thi s ti me) the
four fan hub-to-water pump pul l ey mounti ng nuts
(Fi g. 27).
NOTE: The engine accessory drive belt must be
removed prior to removing the fan (if installed at
pump) or fan pulley.
(7) Remove engi ne dri ve bel t.
(8) Remove power steeri ng pump (Fi g. 28), refer to
Group 19 Steeri ng.
Fig. 25 Reverse Rotating Water PumpTypical
FRONT VIEW ROTATION DIRECTION AS VIEWED BACK VIEW
ROTATION DIRECTION AS VIEWED
Fig. 26 Water Pump Pulley Bolts
WATER PUMP HUB BOLTS (4) PUMP PULLEY
6094) (Fig. 29) SNAP-ON CLAMP TOOL (NUMBER
(9) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump fi tti ng.
(10) Remove four nuts or bol ts previ ousl y l oosened
and remove the fan bl ade assembl y and pul l ey (i f fan
i s i nstal l ed at pump), or remove the pul l ey from the
vehi cl e.
(11) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
Fig. 28 Power Steering Pump Attachment
PUMP BRACKET PUMP ASSEMBLY
Fig. 27 Fan Mounting Nuts
THERMAL VIS- COUS FAN DRIVE (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS (4) FAN HUB-TO-PUMP PULLEY STUDS WATER PUMP WATER PUMP PUL- LEY FAN BLADE (4) FAN HUB-TO-PUMP PULLEY NUTS
(12) Remove the four pump mounti ng bol ts (Fi g.
31) and remove pump from vehi cl e. Di scard ol d gas-
ket. Note that one of the four bol ts i s l onger than the
other bol ts.
(13) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
INSTALLATION
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose fi tti ng to the pump. Use a seal ant on the fi tti ng
such as Mopar Thread Seal ant Wi th Tefl on. Refer
to the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
pump mati ng surfaces for erosi on or damage from
cavi tati on.
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 30 Nm (22 ft. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
(5) Posi ti on water pump pul l ey to water pump
hub.
(6) I f equi pped wi th a water pump mounted fan,
i nstal l fan and four nuts to water pump hub. I f not
equi pped wi th a water pump mounted fan, i nstal l
four pump hub bol ts. Ti ghten bol ts (or nuts) to 27
(7) I nstal l power steeri ng pump.
CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. Refer to
the Belt Removal and Installtion in this group for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.
(8) Adjust accessory dri ve bel t, refer to Accessory
Dri ve Bel t removal and i nstal l ati on i n thi s group.
(9) Fi l l cool i ng system wi th cool ant and check for
l eaks. Refer to Refi l l i ng Cool i ng System i n thi s
group.
(10) Connect battery cabl e to battery.
(11) Start and warm the engi ne. Check for l eaks.
WATER PUMP 5. 2/5. 9L ENGINES
The water pump on 5.2/5.9L engi nes i s bol ted
di rectl y to the engi ne ti mi ng chai n case/cover.
A gasket i s used as a seal between the water pump
and ti mi ng chai n case/cover.
I f water pump i s repl aced because of beari ng/shaft
damage, or l eaki ng shaft seal , the mechani cal cool i ng
fan assembl y shoul d al so be i nspected. I nspect for
fati gue cracks, l oose bl ades, or l oose ri vets that coul d
have resul ted from excessi ve vi brati on. Repl ace fan i f
TYPICAL CONSTANT TENSION HOSE CLAMP TYPICAL HOSE CLAMP NUMBER/LETTER LOCATION
Fig. 31 Water Pump Remove/InstallTypical
(4) PULLEY MOUNTING STUDS HEATER HOSE FITTING UPPER VENT HOLE PUMP GAS- KET WATER PUMP LOWER VENT HOLE LONG BOLT BOLTS (3) SHORT
any of these condi ti ons are found. Al so check condi -
ti on of the thermal vi scous fan dri ve. Refer to Vi scous
Fan Dri ve i n thi s group.
REMOVAL
(1) Di sconnect negati ve battery cabl e from battery.
(2) Drai n cool i ng system. Refer to Drai ni ng Cool -
i ng System i n thi s group.
Do not waste reusabl e cool ant. I f sol uti on i s cl ean,
drai n cool ant i nto a cl ean contai ner for reuse.
(3) The thermal vi scous fan dri ve i s attached
(threaded) to the water pump hub shaft (Fi g. 32).
Remove fan/vi scous fan dri ve assembl y from water
pump by turni ng mounti ng nut countercl ockwi se as
vi ewed from front. Threads on vi scous fan dri ve are
RIGHT HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummi ns Di esel Tool
Set number 2017DSP) can be used. Pl ace a bar or
screwdri ver between water pump pul l ey bol ts (Fi g.
32) to prevent pul l ey from rotati ng. Do not attempt
to remove fan/vi scous fan dri ve assembl y from vehi -
cl e at thi s ti me.
(4) I f water pump i s bei ng repl aced, do not unbol t
fan bl ade assembl y (Fi g. 32) from thermal vi scous
fan dri ve.
(5) Remove two fan shroud-to-radi ator nuts (Fi g.
33). Do not attempt to remove fan shroud at thi s
ti me.
(6) Remove fan shroud and fan bl ade/vi scous fan
dri ve assembl y from vehi cl e as a compl ete uni t.
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
(8) Do not remove water pump pul l ey bol ts at
thi s ti me.
(9) Remove accessory dri ve bel t as fol l ows: The
dri ve bel t i s equi pped wi th a spri ng l oaded automati c
bel t tensi oner (Fi g. 34). Rel ax tensi on from bel t by
rotati ng tensi oner cl ockwi se (as vi ewed from front)
(Fi g. 34). When al l bel t tensi on has been rel axed,
remove accessory dri ve bel t.
(10) Remove four water pump pul l ey-to-water
pump hub bol ts (Fi g. 32) and remove pul l ey from
vehi cl e.
Fig. 32 Fan Blade and Viscous Fan Drive5.2/
5.9LEngines
WATER
PUMP PUL-
LEY
Fig. 33 Fan Shroud Nuts
CONDENSER BOLT FAN SHROUD MOUNTING NUTS UPPER BRACE BOLTS CONDENSER BOLT ALIGNMENT DOWELS LOWER BRACKETBOLT HOOD LATCH BRACKET
(11) Remove l ower radi ator hose cl amp and remove
l ower hose at water pump.
(12) Remove heater hose cl amp (Fi g. 35) and
heater hose from heater hose cool ant return tube.
(13) Loosen heater hose cool ant return tube
mounti ng bol t and nut (Fi g. 35) and remove tube
from water pump. Di scard the ol d tube o-ri ng.
(14) Remove seven water pump mounti ng bol ts
(Fi g. 36).
(15) Loosen cl amp at water pump end of bypass
hose (Fi g. 32). Sl i p bypass hose from water pump
whi l e removi ng pump from vehi cl e. Di scard ol d gas-
ket.
CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
INSTALLATION
(1) Cl ean gasket mati ng surfaces.
(2) Usi ng a new gasket, i nstal l water pump to
engi ne as fol l ows: Gui de water pump ni ppl e i nto
bypass hose as pump i s bei ng i nstal l ed. I nstal l water
pump bol ts (Fi g. 36). Ti ghten water pump mounti ng
(3) Posi ti on bypass hose cl amp to bypass hose.
(4) Spi n water pump to be sure that pump i mpel -
l er does not rub agai nst ti mi ng chai n case/cover.
(5) I nstal l a new o-ri ng to the heater hose cool ant
return tube (Fi g. 35). Coat the new o-ri ng wi th anti -
freeze before i nstal l ati on.
(6) I nstal l cool ant return tube to engi ne (Fi g. 35).
Be sure the sl ot i n tube bracket i s bottomed to the
mounti ng bol t. Thi s wi l l properl y posi ti on return
tube.
(7) Connect radi ator l ower hose to water pump.
(8) Connect heater hose and hose cl amp to cool ant
return tube.
(9) I nstal l water pump pul l ey. Ti ghten bol ts to 27
Nm (20 ft. l bs.) torque. Pl ace a bar or screwdri ver
between water pump pul l ey bol ts (Fi g. 32) to prevent
pul l ey from rotati ng.
(10) Rel ax tensi on from bel t tensi oner (Fi g. 34).
I nstal l dri ve bel t.
Fig. 34 Belt Tensioner Assembly5.2/5.9LEngines
IDLER PULLEY
TURN CLOCKWISE TO REMOVE
BELT
TENSIONER FAN BLADE
Fig. 35 Coolant Return Tube5.2/5.9LEngines
Fig. 36 Water Pump Bolts5.2/5.9L Engines
Typical
WATER PUMP MOUNT- ING BOLTS
CAUTION: When installing the serpentine acces-
sory drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 37) for correct belt
routing. Or, refer to the Belt Routing Label located
in the engine compartment. The correct belt with
correct length must be used.
(11) Posi ti on fan shroud and fan bl ade/vi scous fan
dri ve assembl y to vehi cl e as a compl ete uni t.
(12) Be sure the upper and l ower porti ons of the
fan shroud are fi rml y connected. Al l ai r must fl ow
through the radi ator.
(13) I nstal l two fan shroud-to-radi ator nuts (Fi g.
33).
(14) Be sure of at l east 25 mm (1.0 i nches)
between ti ps of fan bl ades and fan shroud.
(15) I nstal l fan bl ade/vi scous fan dri ve assembl y to
water pump shaft.
(16) Fi l l cool i ng system. Refer to Refi l l i ng the
(17) Connect negati ve battery cabl e.
THERMOSTAT 4. 0L ENGINE
REMOVAL
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusabl e cool ant. I f the sol uti on i s
reuse.
(1) Drai n the cool ant from the radi ator unti l the
l evel i s bel ow the thermostat housi ng.
(2) Remove radi ator upper hose and heater hose at
thermostat housi ng.
(3) Di sconnect wi ri ng connector at engi ne cool ant
temperature sensor.
(4) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng, gasket and thermostat (Fi g. 38).
Di scard ol d gasket.
(5) Cl ean the gasket mati ng surfaces.
Fig. 37 Belt Routing5.2/5.9L Engines
IDLER PULLEY
GEN. A/C COMP.
IF W/OUT A/C
PWR. STRG.
PUMP
WAT.PUMP
CRANK
PULLEY
AUTOMATIC TEN- SIONER *IF VEHICLE IS NOT EQUIPPED WITH POWER STEERING, THIS WILL BE AN IDLER PULLEY.
Fig. 38 Thermostat Removal/Installation
4.0LEngine
LONGBOLT GASKET THERMOSTAT THERMOSTAT HOUSING SHORT BOLT
INSTALLATION
(1) I nstal l the repl acement thermostat so that the
pel l et, whi ch i s enci rcl ed by a coi l spri ng, faces the
engi ne. Al l thermostats are marked on the outer
fl ange to i ndi cate the proper i nstal l ed posi ti on.
(a) Observe the recess groove i n the engi ne cyl -
i nder head (Fi g. 39).
(b) Posi ti on thermostat i n groove wi th arrow and
ai r bl eed hol e on outer fl ange poi nti ng up.
(2) I nstal l repl acement gasket and thermostat
housi ng.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess,
may result in a cracked housing.
(3) Ti ghten the housi ng bol ts to 22 Nm (16 ft. l bs.)
torque.
(4) I nstal l hoses to thermostat housi ng.
(5) I nstal l el ectri cal connector to cool ant tempera-
ture sensor.
(6) Be sure that the radi ator drai ncock i s ti ghtl y
cl osed. Fi l l the cool i ng system to the correct l evel
wi th the requi red cool ant mi xture. Refer to Refi l l i ng
THERMOSTAT 5. 2/5. 9L ENGINES
REMOVAL
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
I f thermostat i s bei ng repl aced, be sure that
repl acement i s speci fi ed thermostat for vehi cl e model
and engi ne type.
Factory i nstal l ed thermostat housi ngs on 5.2/5.9L
engi nes are i nstal l ed on a gasket wi th an anti -sti ck
coati ng. Thi s wi l l ai d i n gasket removal and cl ean-up.
(2) Drai n cool i ng system unti l cool ant l evel i s
bel ow thermostat. Refer to Drai ni ng Cool i ng System
i n thi s group.
(3) Ai r Condi ti oned vehi cl es: Remove support
bracket (generator mounti ng bracket-to-i ntake mani -
fol d) l ocated near rear of generator (Fi g. 40).
(4) On ai r condi ti oni ng equi pped vehi cl es, the gen-
erator must be parti al l y removed.
(a) Remove generator dri ve bel t as fol l ows: Dri ve
bel ts on the 5.2/5.9L engi nes are equi pped wi th a
spri ng l oaded automati c bel t tensi oner (Fi g. 41).
(b) Attach a socket/wrench to pul l ey mounti ng
bol t of automati c bel t tensi oner (Fi g. 41).
(c) Rotate tensi oner assembl y cl ockwi se (as
vi ewed from front) unti l tensi on has been rel i eved
from bel t.
Fig. 39 Thermostat Recess4.0L Engine
GROOVE
Fig. 40 Generator Support Bracket5.2/5.9LEngines
GENERATOR/COMPRESSOR AND BRACKET SUPPORT BRACKET AUTOMATIC BELT TEN- SIONER IGNITION COIL BRACKET IDLER PULLEY
(d) Remove bel t from vehi cl e.
(e) Remove two generator mounti ng bol ts. Do
not remove any wi ri ng at generator. I f equi pped
wi th 4WD, unpl ug 4WD i ndi cator l amp wi ri ng har-
ness (l ocated near rear of generator).
(f) Remove generator. Posi ti on generator to gai n
access for thermostat gasket removal .
(5) Remove upper radi ator hose cl amp (Fi g. 53)
and upper radi ator hose at thermostat housi ng.
(6) Posi ti on wi ri ng harness (behi nd thermostat
housi ng) to gai n access to thermostat housi ng.
(7) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng, gasket and thermostat (Fi g. 42).
Di scard ol d gasket.
INSTALLATION
(1) Cl ean mati ng areas of i ntake mani fol d and
thermostat housi ng.
(2) I nstal l thermostat (spri ng si de down) i nto
recessed machi ned groove on i ntake mani fol d (Fi g.
42).
(3) I nstal l gasket on i ntake mani fol d and over
thermostat (Fi g. 42).
(4) Posi ti on thermostat housi ng to i ntake mani fol d.
Note the word FRONT stamped on housi ng (Fi g. 43).
For adequate cl earance, thi s must be pl aced towards
front of vehi cl e. The housi ng i s sl i ghtl y angl ed for-
ward after i nstal l ati on to i ntake mani fol d.
(5) I nstal l two housi ng-to-i ntake mani fol d bol ts.
Ti ghten bol ts to 23 Nm (200 i n. l bs.) torque.
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
in intake manifold. If not, it may result in a cracked
housing, damaged intake manifold threads or cool-
ant leak.
(6) I nstal l upper radi ator hose to thermostat hous-
i ng.
(7) Ai r Condi ti oned vehi cl es:
Fig. 41 Automatic Belt Tensioner5.2/5.9LEngines
IDLER PULLEY
BELT
TENSIONER FAN BLADE
Fig. 42 Thermostat5.2/5.9L Engines
THERMOSTAT HOUSING GASKET INTAKE MANIFOLD THERMOSTAT MACHINED GROOVE
Fig. 43 Thermostat Position5.2/5.9LEngines
FRONT
sory drive belt, belt must be routed correctly. If not,
wrong direction. Refer to (Fig. 44) for correct
5.2/5.9L engine belt routing. Or, refer to the Belt
Routing Label located in the engine compartment.
The correct belt with correct length must be used.
(a) I nstal l generator. Ti ghten bol ts to 41 Nm (30
ft. l bs.) torque.
(b) I nstal l support bracket (generator mounti ng
bracket-to-i ntake mani fol d) (Fi g. 40). Ti ghten bol ts
(c) Posi ti on dri ve bel t over al l pul l eys except
i dl er pul l ey (l ocated between generator and A/C
compressor).
(d) Attach a socket/wrench to pul l ey mounti ng
bol t of automati c bel t tensi oner (Fi g. 41).
(e) Rotate socket/wrench cl ockwi se. Pl ace bel t
over i dl er pul l ey. Let tensi oner rotate back i nto
pl ace. Remove wrench. Be sure bel t i s properl y
seated on al l pul l eys.
(8) Fi l l cool i ng system. Refer to Refi l l i ng Cool i ng
System i n thi s group.
RADIATOR
REMOVAL
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING IN THIS GROUP.
Do not waste reusabl e cool ant. I f the sol uti on i s
reuse.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 47). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
To prevent overheating, these seals must be
installed to their original positions.
(1) Di sconnect the negati ve battery cabl e at bat-
tery.
(2) Observe the previ ous WARNI NGS and CAU-
TI ONS.
(3) Drai n cool ant from radi ator. Refer to Drai ni ng
IDLER PULLEY
GEN. A/C COMP.
IF W/OUT A/C
PWR. STRG.
PUMP
WAT.PUMP
CRANK
PULLEY
(4) 4.0L Engine: Remove the four fan hub-to-wa-
ter pump pul l ey mounti ng nuts (Fi g. 48). Careful l y
remove the fan assembl y from the water pump pul l ey
and posi ti on to center of fan shroud. Fan bel t
removal i s not necessary as the water pump studs
wi l l hol d the pump pul l ey i n posi ti on.
(5) Do not remove fan/vi scous fan dri ve assembl y
from vehi cl e at thi s ti me.
(6) 5.2/5.9L Engines: The thermal vi scous fan
dri ve i s attached (threaded) to the water pump hub
shaft (Fi g. 49). Remove fan/vi scous fan dri ve assem-
bl y from water pump by turni ng mounti ng nut coun-
tercl ockwi se as vi ewed from front. Threads on
vi scous fan dri ve are RIGHT HAND. A Snap-On 36
MM Fan Wrench (number SP346 from Snap-On
Cummi ns Di esel Tool Set number 2017DSP) can be
used. Pl ace a bar or screwdri ver between water
pump pul l ey bol ts (Fi g. 49) to prevent pul l ey from
rotati ng. Dri ve bel t removal i s not necessary for
removal of fan dri ve.
(7) Do not attempt to remove fan/vi scous fan dri ve
assembl y from vehi cl e at thi s ti me.
(8) Remove the two fan shroud-to-upper radi ator
crossmember mounti ng nuts (Fi g. 50).
(9) Remove the fan assembl y and fan shroud (as
one uni t) from vehi cl e.
(10) Speci al qui ck-connect fi tti ngs are used to joi n
the transmi ssi on cool i ng l i nes to the radi ator.
Removal procedures are di fferent between the 4.0L
and 5.2/5.9L engi nes. Di sconnect the cool i ng l i nes
Fig. 47 Air SealsTypical
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
TYPICAL CONSTANT TENSION HOSE CLAMP CLAMP NUMBER/ LETTER LOCA- TION TYPICAL HOSE
from the radi ator. Refer to Group 21 for transmi ssi on
cool i ng l i ne removal and i nstal l ati on.
(11) The radi ator upper crossmember (Fi g. 51) can
be adjusted l eft or ri ght through the use of sl otted
hol es. Before removal , mark the ori gi nal posi ti on of
the crossmember.
(12) Ei ght cl i ps are used to retai n a rubber seal
(Fi g. 51) to the body and upper radi ator crossmem-
ber. Gentl y pry up the outboard cl i ps (two per si de)
unti l rubber seal can be removed. Do not remove the
cl i ps enti rel y. Fol d back the seal on both si des for
access to (the hi dden) gri l l e openi ng rei nforcement
mounti ng bol ts (Fi g. 51). Remove these two bol ts.
(13) Remove the gri l l . Refer to group 23, Body.
(14) Remove the upper brace bol t from each of the
two radi ator braces (Fi g. 50).
(15) Remove the two crossmember-to-radi ator
mounti ng nuts (Fi g. 51).
(16) Worki ng through gri l l openi ng, remove the
l ower bracket bol t securi ng l ower part of hood l atch
Fig. 48 Fan Mounting Nuts4.0L 6-Cyl.Engine
THERMAL VIS- COUS FAN DRIVE (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS (4) FAB HUB-TO-PUMP PULLEY STUDS WATER PUMP WATER PUMP PUL- LEY FAN BLADE (4) FAN HUB-TO-PUMP PULLEY NUTS
Fig. 49 Fan Blade and Viscous Fan Drive5.2/5.9LV-
8 Engines
WATER
PUMP PUL-
LEY
Fig. 50 Radiator and A/C Condenser Mounting
Fig. 51 Radiator Upper CrossmemberTypical
RADIATOR UPPER CROSS- MEMBER RUBBER SEAL OVERFLOWHOSE CROSSMEMBER-TO-RA- DIATOR MOUNTING NUTS OUTERCLIPS HIDDEN BOLT
HOOD LATCH
CLIP HIDDEN BOLT OUTER CLIPS
support bracket to l ower frame crossmember (Fi g.
50).
(17) Remove the remai ni ng four bol ts securi ng 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 to the si de.
(18) Equi pped wi th ai r condi ti oni ng: Remove the
two A/C condenser-to-radi ator mounti ng bol ts (Fi g.
50). These two bol ts are al so used to retai n the si de
mounted rubber ai r seal s (Fi g. 47). These seal s are
compressed between the A/C condenser and the radi -
ator. The l ower part of the ai r seal s are compressed
between the radi ator and the A/C condenser mount-
i ng brackets (Fi g. 52).
(19) Not equi pped wi th ai r condi ti oni ng: Remove
the two bol ts retai ni ng the si de mounted rubber ai r
seal s (Fi g. 47) to the radi ator. The l ower part of the
ai r seal s are compressed between the radi ator and
the radi ator l ower crossmember.
CAUTION: Note the location of all rubber air seals
(Fig. 47). To prevent overheating, they must be
installed back to their original positions.
(20) Di sconnect the cool ant reserve/overfl ow tank
hose (Fi g. 51) at radi ator.
(21) Remove upper radi ator hose at radi ator. A
speci al cl amp tool (Fi g. 45) must be used to remove
the constant tensi on hose cl amps.
(22) 4.0L Engi ne Onl y: Remove the l ower radi ator
hose at the water pump end.
(23) To gai n access to l ower radi ator hose cl amp at
radi ator, gentl y l i ft the radi ator a sl i ght amount.
Remove hose cl amp and hose.
(24) The l ower part of radi ator i s equi pped wi th
two al i gnment dowel pi ns (Fi g. 50) (Fi g. 52). They
are l ocated on the bottom of radi ator tank and fi t
i nto rubber grommets. These rubber grommets are
pressed i nto the radi ator l ower crossmember.
WARNING: THE AIR CONDITIONING SYSTEM (IF
EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN GROUP 24, HEATING AND
AIR CONDITIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.
(25) I f equi pped wi th an auxi l i ary automati c trans-
mi ssi on oi l cool er, use cauti on when removi ng radi a-
tor. The oi l cool er l i nes are routed through a rubber
ai r seal on the l eft si de of radi ator. Do not cut or tear
thi s seal .
(26) Gentl y l i ft up and remove radi ator from vehi -
cl e. Be careful not to scrape the radi ator fi ns agai nst
any other component. Al so be careful not to di sturb
the ai r condi ti oni ng condenser (i f equi pped).
INSTALLATION
CAUTION: Before installing the radiator or A/C
condenser, be sure the radiator-to-body and radia-
tor-to-A/C condenser rubber air seals (Fig. 47) are
properly fastened to their original positions. These
are used at the top, bottom and sides of the radia-
tor and A/C condenser. To prevent overheating,
these seals must be installed to their original posi-
tions.
(1) Equi pped wi th ai r condi ti oni ng: Gentl y l ower
the radi ator i nto the vehi cl e. Gui de the two radi ator
al i gnment dowel s through the hol es i n the rubber ai r
seal s fi rst and then through the A/C support brackets
(Fi g. 52). Conti nue to gui de the al i gnment dowel s
i nto the rubber grommets l ocated i n l ower radi ator
crossmember (Fi g. 52). The hol es i n the L-shaped
brackets (l ocated on bottom of A/C condenser) must
be posi ti oned between bottom of rubber ai r seal s and
top of rubber grommets.
(2) Not equi pped wi th ai r condi ti oni ng: Gentl y
l ower the radi ator i nto the vehi cl e. Gui de the two
radi ator al i gnment dowel s through the hol es i n the
rubber ai r seal s. Conti nue to gui de the al i gnment
dowel s i nto the rubber grommets l ocated i n l ower
radi ator crossmember.
Fig. 52 Radiator Alignment Dowels
RADIATOR ALIGNMENT DOWEL RADIATOR LOWER CROSSMEMBER RUBBER GROMMET RUBBER AIR SEAL A/C CONDENSER SUPPORTBRACKET
(3) Connect the l ower radi ator hose and hose
cl amp to radi ator.
CAUTION: The tangs on the hose clamp must be
positioned straight down.
(4) 4.0L Engi ne: Connect the l ower radi ator hose
at the water pump.
(5) Connect the upper radi ator hose at the radi a-
tor.
(6) Equi pped wi th ai r condi ti oni ng: I nstal l the two
A/C condenser- to-radi ator mounti ng bol ts (Fi g. 50).
These two bol ts are al so used to retai n the rubber ai r
seal (Fi g. 47) to the si des of radi ator.
(7) Not equi pped wi th A/C: I nstal l the two bol ts
retai ni ng the rubber ai r seal (Fi g. 47) to si des of radi -
ator.
(8) I nstal l cool ant reserve/overfl ow tank hose at
radi ator.
(9) I f radi ator-to-upper crossmember rubber i sol a-
tors were removed from radi ator, i nstal l them.
Ti ghten mounti ng nuts to 3 Nm (24-36 i n. l bs.)
torque. Posi ti on upper radi ator crossmember to radi -
ator.
(10) Worki ng through gri l l openi ng, i nstal l and
ti ghten the hood l atch support bracket-to-l ower frame
crossmember bol t (Fi g. 50).
(11) I nstal l the four bol ts securi ng the radi ator
upper crossmember to the body (Fi g. 51).
(12) I nstal l two nuts securi ng the radi ator to the
upper radi ator crossmember (Fi g. 51). Ti ghten nuts
to 2 Nm (18-21 i n. l bs.) torque.
(13) I nstal l the upper bol t to each radi ator brace
(Fi g. 50).
(14) I nstal l the gri l l . Refer to group 23, Body.
(15) I nstal l the rubber seal (Fi g. 51) to the four
(outer) seal mounti ng cl i ps on vehi cl e body. Press
down on cl i ps unti l seated.
(16) I nstal l the transmi ssi on cool er l i nes to radi a-
tor. Refer to Group 21 for i nstal l ati on.
(17) Posi ti on the fan assembl y and fan shroud (as
one uni t) to the vehi cl e.
(18) Posi ti on fan shroud to radi ator. Be sure the
al i gnment tabs at the l ower part of shroud are pl aced
i nto the sl ots near l ower part of radi ator.
Be sure the upper and l ower porti ons of the fan
shroud are fi rml y connected. Al l ai r must fl ow
(19) I nstal l the two nuts securi ng the fan shroud
to the upper radi ator crossmember (Fi g. 50).
(20) 4.0L Engi ne: I nstal l the four nuts securi ng
the fan assembl y to the water pump (Fi g. 48).
Ti ghten nuts to 27 Nm (20 ft. l bs.) torque.
(21) 5.2/5.9L Engi nes: I nstal l the fan/vi scous fan
dri ve assembl y to the water pump.
(22) Rotate the fan bl ades (by hand) and check for
i nterference at fan shroud.
(23) Be sure of at l east 25 mm (1.0 i nches)
between ti ps of fan bl ades and fan shroud.
(24) Fi l l cool i ng system. Refer to Refi l l i ng Cool i ng
System i n thi s group.
(25) Connect battery cabl e at battery.
(26) Start and warm engi ne. Check for l eaks.
WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING
REMOVAL
(1) Parti al l y drai n cool i ng system. Refer to Drai n-
i ng Cool i ng System i n thi s group.
(2) Do not waste reusabl e cool ant. I f sol uti on i s
(3) Loosen both bypass hose cl amps (Fi g. 53) and
posi ti on to center of hose. Remove hose from vehi cl e.
INSTALLATION
(1) Posi ti on bypass hose cl amps (Fi g. 53) to center
of hose.
(2) I nstal l bypass hose to engi ne.
(3) Secure both hose cl amps (Fi g. 53).
(4) Fi l l cool i ng system. Refer to Refi l l i ng the Cool -
WITH AIR CONDITIONING
REMOVAL
I f equi pped wi th A/C, the generator and A/C com-
pressor al ong wi th thei r common mounti ng bracket
(Fi g. 55) must be parti al l y removed. Removi ng gener-
ator or A/C compressor from thei r mounti ng bracket
i s not necessary. Al so, di schargi ng A/C system i s not
necessary. Do not remove any refri gerant l i nes from
A/C compressor.
WARNING: THE A/C SYSTEM IS UNDER PRES-
SURE EVEN WITH ENGINE OFF. REFER TO
REFRIGERANT WARNINGS IN GROUP 24, HEATING
AND AIR CONDITIONING.
(2) Parti al l y drai n cool i ng system. Refer to Drai n-
i ng Cool i ng System i n thi s group.
(3) Remove upper radi ator hose cl amp (Fi g. 53)
and hose at radi ator.
(4) Unpl ug wi ri ng harness from A/C compressor.
(5) Remove ai r duct at throttl e body.
(6) Di sconnect A/C l i nes from cl i p at i ntake mani -
fol d.
(7) Remove heater hose cool ant return tube mount-
i ng bol t and nut (Fi g. 56). Remove tube from engi ne
and di scard the ol d tube o-ri ng.
(8) Remove accessory dri ve bel t as fol l ows: The
dri ve bel t i s equi pped wi th a spri ng l oaded automati c
bel t tensi oner (Fi g. 57). Rel ax tensi on from bel t by
rotati ng tensi oner cl ockwi se (as vi ewed from front)
TYPICAL CONSTANT TENSION HOSE CLAMP CLAMP NUMBER/ LETTER LOCA- TION TYPICAL HOSE
Fig. 55 Generator and A/C Compressor
MountingBracket5.2/5.9L Engines
GENERATOR/COMPRESSOR AND BRACKET SUPPORT BRACKET AUTOMATIC BELT TEN- SIONER IGNITION COIL BRACKET IDLER PULLEY
Fig. 56 Coolant Return Tube5.2/5.9LEngines
(Fi g. 57). When al l bel t tensi on has been rel axed,
remove accessory dri ve bel t.
(9) The dri ve bel t i dl er pul l ey must be removed to
gai n access to one of A/C compressor/generator
bracket mounti ng bol ts. Remove i dl er pul l ey bol t and
remove i dl er pul l ey (Fi g. 55).
(10) Remove oi l di psti ck tube mounti ng bol t at si de
of A/C- generator mounti ng bracket.
(11) Di sconnect speed control cabl e and throttl e
cabl e at throttl e body. Refer to Accel erator Pedal and
Throttl e Cabl e i n Group 14, Fuel System for throttl e
cabl e removal and i nstal l ati on. Refer to Group 8H for
removal and i nstal l ati on of speed control cabl e.
(12) Remove bracket-to-i ntake mani fol d bol ts
(number 1 and 2) (Fi g. 55).
(13) Remove bracket bol ts (Fi g. 55).
(14) Li ft and posi ti on generator and A/C compres-
sor (al ong wi th thei r common mounti ng bracket) to
gai n access to bypass hose. A bl ock of wood may be
used to hol d assembl y i n posi ti on.
(15) Loosen and posi ti on both hose cl amps to cen-
ter of bypass hose. Remove hose from vehi cl e.
INSTALLATION
(1) Posi ti on bypass hose cl amps to center of hose.
(2) I nstal l bypass hose to engi ne.
(3) Secure both hose cl amps (Fi g. 53).
(4) I nstal l generator-A/C mounti ng bracket assem-
bl y to engi ne. Ti ghten bol ts (number 1 and 2) (Fi g.
55) to 54 Nm (40 ft. l bs.) torque. Ti ghten bol ts (num-
ber 3) (Fi g. 55) to 40 Nm (30 ft. l bs.) torque.
(5) I nstal l a new o-ri ng to the heater hose cool ant
return tube (Fi g. 56). Coat the new o-ri ng wi th anti -
freeze before i nstal l ati on.
(6) I nstal l cool ant return tube to engi ne (Fi g. 56).
Be sure the sl ot i n tube bracket i s bottomed to the
mounti ng bol t. Thi s wi l l properl y posi ti on return
tube.
(7) Connect throttl e body control cabl es.
(8) I nstal l oi l di psti ck mounti ng bol t.
(9) I nstal l i dl er pul l ey. Ti ghten pul l ey bol t to 54
(10) Rel ax tensi on from bel t tensi oner (Fi g. 57).
I nstal l dri ve bel t.
CAUTION: When installing serpentine accessory
drive belt, belt must be routed correctly. If not,
wrong direction. Refer to (Fig. 58) for correct belt
routing. Or, refer to the Belt Routing Label located
in the engine compartment. The correct belt with
correct length must be used.
(11) I nstal l ai r duct to throttl e body.
(12) I nstal l upper radi ator hose to radi ator.
(13) Connect wi ri ng harness to A/C compressor.
(14) Connect A/C l i nes to cl i p at i ntake mani fol d.
(15) Fi l l cool i ng system. Refer to Refi l l i ng the
ENGINE BLOCK HEATER
REMOVAL
Fig. 57 Belt Tensioner Assembly5.2/5.9LEngines
IDLER PULLEY
BELT
TENSIONER FAN BLADE
IDLER PULLEY
GEN. A/C COMP.
IF W/OUT A/C
PWR. STRG.
PUMP
WAT.PUMP
CRANK
PULLEY
(2) Drai n cool ant from radi ator. Refer to Drai ni ng
(4) Remove engi ne cyl i nder bl ock drai n pl ug(s)
l ocated on the si des of cyl i nder bl ock above the oi l
pan rai l (Fi g. 59) (Fi g. 60).
(5) Remove power cord from bl ock heater (Fi g. 61)
(Fi g. 62).
(6) Loosen screw at center of bl ock heater. Remove
heater assembl y.
INSTALLATION
(1) Thoroughl y cl ean cyl i nder bl ock core hol e and
bl ock heater seat.
(2) I nsert bl ock heater assembl y wi th el ement l oop
poi nti ng down.
(3) Wi th bl ock heater ful l y seated, ti ghten center
screw to 2 Nm (17 i n. l bs.) torque.
(4) Fi l l cool i ng system wi th recommended cool ant.
Refer to Refi l l i ng Cool i ng System secti on i n thi s
group.
BELT REPLACEMENT/ADJUSTMENT
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Fig. 59 Drain Plug4.0L 6-CylinderEngine
COOLANT TEMPERATURE SENSOR BLOCK DRAIN PLUG
Fig. 60 Drain Plugs5.2/5.9L V-8 Engines
BLOCK DRAIN
PLUG
Fig. 61 Block Heater4.0L Engine
POWER CORD LOCA- TION BLOCK HEATER
Fig. 62 Block Heater5.2/5.9L Engines
LOWER ENGINE BLOCK POWERCORD BLOCKHEATER
4.0L ENGINE
REMOVAL
Bel t tensi on i s adjusted at the power steeri ng
pump bracket and i dl er pul l ey assembl y.
(2) Loosen bel t tensi on at power steeri ng pump
bracket and i dl er pul l ey (Fi g. 63).
(3) Remove bel t.
INSTALLATION
(1) Check condi ti on of al l pul l eys.
sory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water
pump rotating in the wrong direction (Fig. 64).
(2) I nstal l new bel t. Refer to the end of thi s group
for Dri ve Bel t Tensi on speci fi cati ons.
(3) After power steeri ng pump bracket and i dl er
pul l ey has been ti ghtened i nto posi ti on, recheck bel t
tensi on. Adjust i f necessary.
5.2/5.9L Engines
Dri ve bel ts on the 5.2/5.9L engi nes are equi pped
wi th a spri ng l oaded automati c bel t tensi oner (Fi g.
65).
CAUTION: Do not attempt to check belt tension
with a belt tension gauge on vehicles equipped with
an automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
REMOVAL
(1) Attach a socket/wrench to pul l ey mounti ng bol t
of automati c bel t tensi oner (Fi g. 65).
(2) Rotate tensi oner assembl y cl ockwi se (as vi ewed
from front) unti l tensi on has been rel i eved from bel t.
(3) Remove bel t from i dl er pul l ey fi rst.
(4) Remove bel t from vehi cl e.
Fig. 63 Power Steering Pump Bracket and IdlerPulley
PUMP ASSEMBLY PUMP BRACKET
Fig. 64 Belt Routing4.0L Engine
AC+
IDL
+
ALT+ WP & FAN+ PS+ IDL +
CRANK
+
INSTALLATION
CAUTION: When installing serpentine accessory
drive belt, the belt must be routed correctly. If not,
wrong direction. Refer to (Fig. 66) for correct engine
belt routing. The correct belt with correct length
must be used.
(1) Posi ti on dri ve bel t over al l pul l eys except i dl er
pul l ey. Thi s pul l ey i s l ocated between generator and
A/C compressor.
(2) Attach a socket/wrench to pul l ey mounti ng bol t
of automati c tensi oner (Fi g. 65).
(3) Rotate socket/wrench cl ockwi se. Pl ace bel t over
i dl er pul l ey. Let tensi oner rotate back i nto pl ace.
Remove wrench. Be sure bel t i s properl y seated on
al l pul l eys.
(4) Check bel t i ndexi ng marks. Refer to Automati c
Bel t Tensi oner.
AUTOMATIC BELT TENSIONER
NOTE: On 5.2/5.9L engines, the tensioner is
equipped with an indexing arrow (Fig. 67) on back
of tensioner and an indexing mark on tensioner
housing. If a new belt is being installed, arrow must
be within approximately 3 mm (1/8 in.) of indexing
mark (point B-) (Fig. 67). Belt is considered new if it
has been used 15 minutes or less.
I f the above speci fi cati on cannot be met, check for:
The wrong bel t bei ng i nstal l ed (i ncorrect l ength/
wi dth)
Worn beari ngs on an engi ne accessory (A/C com-
pressor, power steeri ng pump, water pump, i dl er pul -
l ey or generator)
A pul l ey on an engi ne accessory bei ng l oose
Mi sal i gnment of an engi ne accessory
Bel t i ncorrectl y routed.
NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to point-A (Fig. 67). Ten-
sioner travel stops at point-A.
REMOVAL
(1) Remove accessory dri ve bel t. Refer to Bel t
Repl acement/Adjustment i n thi s group.
(2) Di sconnect wi ri ng and secondary cabl e from
i gni ti on coi l .
(3) Remove i gni ti on coi l from coi l mounti ng
bracket (two bol ts). Do not remove coi l mounti ng
bracket from cyl i nder head.
(4) Remove tensi oner assembl y from mounti ng
bracket (one nut) (Fi g. 67).
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
(5) Remove pul l ey bol t. Remove pul l ey from ten-
si oner.
INSTALLATION
(1) I nstal l pul l ey and pul l ey bol t to tensi oner.
Ti ghten bol t to 61 Nm (45 ft. l bs.) torque.
Fig. 65 Belt Tensioner5.2/5.9L Engines
IDLER PULLEY
BELT
TENSIONER FAN BLADE
IDLER PULLEY
GEN. A/C COMP.
IF W/OUT A/C
PWR. STRG.
PUMP
WAT.PUMP
CRANK
PULLEY
(2) I nstal l tensi oner assembl y to mounti ng
bracket. An i ndexi ng tab i s l ocated on back of ten-
si oner. Al i gn thi s tab to sl ot i n mounti ng bracket.
Ti ghten nut to 67 Nm (50 ft. l bs.) torque.
(3) Connect al l wi ri ng to i gni ti on coi l .
(4) I nstal l coi l to coi l bracket. I f nuts and bol ts are
used to secure coi l to coi l bracket, ti ghten to 11 Nm
(100 i n. l bs.) torque. I f coi l mounti ng bracket has
been tapped for coi l mounti ng bol ts, ti ghten bol ts to 5
Nm (50 i n. l bs.) torque.
CAUTION: To prevent damage to coil case, coil
mounting bolts must be torqued.
(5) I nstal l dri ve bel t. Refer to Bel t Removal /I nstal -
l ati on i n thi s group.
(6) Check bel t i ndexi ng marks (Fi g. 67).
COOLING SYSTEM FAN 4. 0L ENGINE
REMOVAL
(1) Remove the four fan hub-to-water pump pul l ey
mounti ng nuts (Fi g. 68). Careful l y remove the fan
assembl y from the water pump pul l ey and posi ti on to
center of fan shroud. Fan bel t removal i s not neces-
sary as the water pump studs wi l l hol d the pump
pul l ey i n posi ti on. Do not remove fan assembl y from
vehi cl e at thi s ti me.
(2) Remove the two fan shroud-to-upper radi ator
crossmember mounti ng nuts (Fi g. 69).
(3) Remove fan, vi scous fan dri ve and fan shroud
as an assembl y from the vehi cl e.
(4) Remove the four fan bl ade-to-vi scous fan dri ve
mounti ng bol ts. Remove vi scous fan dri ve from fan
bl ades.
Fig. 67 Belt Tensioner/Pulley Assembly5.2/
5.9LEngines
TENSIONER ASSEMBLY TENSIONER MOUNTING NUT INDEXING ARROW INDEXING MARK
Fig. 68 Fan Mounting Nuts4.0L 6-Cyl.Engine
THERMAL VIS- COUS FAN DRIVE (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS (4) FAB HUB-TO-PUMP PULLEY STUDS WATER PUMP WATER PUMP PUL- LEY FAN BLADE (4) FAN HUB-TO-PUMP PULLEY NUTS
Fig. 69 Fan Shroud Mounting Nuts
(5) After removi ng fan bl ade/fan dri ve assembl y do
not pl ace the thermal vi scous fan dri ve i n the hori -
zontal posi ti on. I f stored hori zontal l y, the si l i cone
fl ui d i n the vi scous fan dri ve coul d drai n i nto the
beari ng assembl y and contami nate the l ubri cant.
INSTALLATION
(1) Assembl e fan bl ades to vi scous fan dri ve.
Ti ghten mounti ng bol ts to 24 Nm (18 ft. l bs.) torque.
(2) Posi ti on fan, vi scous fan dri ve and fan shroud
to the engi ne as one assembl y.
i nto the sl ots near l ower part of radi ator.
Be sure the upper and l ower porti ons of the fan
shroud are fi rml y connected. Al l ai r must fl ow
(4) Posi ti on mounti ng fl ange of fan/vi scous fan
dri ve assembl y onto water pump pul l ey. I nstal l four
nuts and ti ghten to 24 Nm (18 ft. l bs.) torque.
(5) I nstal l two fan shroud mounti ng nuts.
Be sure of at l east 25 mm (1.0 i nches) between ti ps
of fan bl ades and fan shroud.
COOLING SYSTEM FAN 5. 2/5. 9L ENGINES
REMOVAL
(2) The thermal vi scous fan dri ve/fan bl ade assem-
bl y i s attached (threaded) to water pump hub shaft
(Fi g. 70). Remove fan bl ade/vi scous fan dri ve assem-
bl y from water pump by turni ng mounti ng nut coun-
tercl ockwi se as vi ewed from front. Threads on
vi scous fan dri ve are RIGHT HAND. A Snap-On 36
MM Fan Wrench (number SP346 from Snap-On
Cummi ns Di esel Tool Set number 2017DSP) can be
used. Pl ace a bar or screwdri ver between water
pump pul l ey bol ts to prevent pul l ey from rotati ng.
(4) Do not unbol t fan bl ade assembl y from vi scous
fan dri ve at thi s ti me.
(5) Remove two fan shroud-to-upper crossmember
nuts (Fi g. 69).
dri ve assembl y as a compl ete uni t from vehi cl e.
assembl y, do not pl ace vi scous fan dri ve i n hori zon-
tal posi ti on. I f stored hori zontal l y, si l i cone fl ui d i n
the vi scous fan dri ve coul d drai n i nto i ts beari ng
CAUTION: Do not remove water pump pulley-to-
water pump bolts. This pulley is under spring ten-
sion.
(8) Remove four bol ts securi ng fan bl ade assembl y
to vi scous fan dri ve.
INSTALLATION
(1) I nstal l fan bl ade assembl y to vi scous fan dri ve.
Ti ghten bol ts to 23 Nm (17 ft. l bs.) torque.
i nto the sl ots near l ower part of radi ator. I nstal l and
ti ghten the two fan shroud-to-upper crossmember
mounti ng nuts.
Be sure of at l east 25 mm (1.0 i nches) between ti ps
of fan bl ades and fan shroud.
water pump shaft.
VISCOUS FAN DRIVE
REMOVAL/INSTALLATION
Refer to Cool i ng System Fan removal and i nstal l a-
ti on procedures of the vi scous fan dri ve uni t proce-
dures.
Viscous Fan Drive Fluid Pump Out Requirement:
After i nstal l i ng a NEWvi scous fan dri ve, bri ng the
engi ne speed up to approxi matel y 2000 rpm and hol d
for approxi matel y two mi nutes. Thi s wi l l ensure
proper fl ui d di stri buti on wi thi n the dri ve.
Fig. 70 Fan Blade/Viscous Fan Drive5.2/5.9LV-8
Engines
WATER
PUMP PUL-
LEY
RADIATOR CAP
INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
RADIATOR
CLEANING
The radi ator and ai r condi ti oni ng fi ns shoul d be
cl eaned when an accumul ati on of bugs, l eaves etc.
has occurred. Cl ean radi ator fi ns are necessary for
good heat transfer. Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
FAN BLADE INSPECTION
The fan bl ades cannot be repai red. I f the fan i s
damaged, i t must be repl aced. I nspect the fan bl ades
as fol l ows:
Lay fan bl ade assembl y on a fl at surface wi th l ead-
i ng edge faci ng down. Wi th ti p of bl ade touchi ng fl at
surface, repl ace fan i f cl earance between opposi te
bl ade and surface i s greater than 2.0 mm (.090 i nch).
Rocki ng moti on of opposi te bl ades shoul d not exceed
2.0 mm (.090 i nch). Test al l bl ades i n thi s manner.
WARNING: IF FAN IS NOT WITHIN SPECIFICA-
TIONS, DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN.
I nspect fan assembl y for cracks, bends, l oose ri vets
or broken wel ds. Repl ace fan i f any damage i s found.
CAUTION: If the fan blade assembly is replaced
because of mechanical damage, the water pump
and viscous fan drive should also be inspected.
These components could have been damaged due
to excessive vibration.
WATER PUMP INSPECTION
Repl ace water pump assembl y i f i t has any of the
fol l owi ng condi ti ons:
The body i s cracked or damaged
Water l eaks from shaft seal . Thi s i s evi dent by
traces of cool ant bel ow vent hol e
Loose or rough turni ng beari ng. Al so i nspect vi s-
cous fan dri ve
I mpel l er rubs ei ther the pump body or ti mi ng
chai n case/cover
SPECIFICATIONS
INFORMATION
The fol l owi ng speci fi cati ons are publ i shed from the
l atest i nformati on avai l abl e at the ti me of publ i ca-
ti on. If anything differs between the specifica-
tions found on the Vehicle Emission Control
Information (VECI) label and the following
specifications, use specifications on VECI label.
The VECI l abel i s l ocated i n the engi ne compart-
ment. Refer to Group 25, Emi ssi on System for more
i nformati on on the VECI l abel .
COOLING SYSTEM CAPACITIES
4.0L (6 cyl. eng.) *
11.4 L (12.0 quarts)
5.2/5.9L (8 cyl. eng.) *
14.1 L (14.9 quarts)
* I ncl udes cool ant recovery bottl e capaci ty
DRIVE BELT TENSION
4.0L (6 cyl. eng.)
* (Wi th new serpenti ne bel t) 800900 N
(180200 l bs. force)
4.0L (6 cyl. eng.)
* (Wi th used serpenti ne bel t) 623712 N
(140160 l bs. force)
5.2/5.9L (V-8 eng.)
Do not attempt to check bel t tensi on wi th a ten-
si on gauge. System i s equi pped wi th an automati c
tensi oner. Refer to Automati c Bel t Tensi oner i f Group
7, Cool i ng System
NOTE: * Specifications for use with a belt tension
gauge. Refer to operating instructions supplied with
gauge.
DESCRIPTION TORQUE
Automatic Belt Tensioner to Mounting Bracket
(5.2/5.9L)
Bol ts . . . . . . . . . . . . . . . . . . . . . . 67 Nm (50 ft. l bs.)
Automatic Belt Tensioner to Block (5.2/5.9L)
Bol ts . . . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Automatic Belt Tensioner Pulley (5.2/5.9L)
Bol t . . . . . . . . . . . . . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Belt Tensioner Bracket to Block (4.0L)
Bol ts . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Belt Idler Pulley (4.0L)
Fi xed Pul l ey Bol t . . . . . . . . . . . . 57 Nm (42 ft. l bs.)
Belt Tensioner Pulley (4.0L)
Bol t . . . . . . . . . . . . . . . . . . . . . . . 57 Nm (42 ft. l bs.)
Block Heater (4.0L)
Bol t . . . . . . . . . . . . . . . . . . . . . . . 4 Nm (32 i n. l bs.)
Block Heater (5.2/5.9L)
Bol t . . . . . . . . . . . . . . . . . . . . . . . 2 Nm (17 i n. l bs.)
Fan BladeAssy. to Viscous Drive (4.0L)
Bol ts . . . . . . . . . . . . . . . . . . . . 23 Nm (200 i n. l bs.)
Fan/DriveAssy. to Water Pump (4.0L)
Nuts . . . . . . . . . . . . . . . . . . . . . 23 Nm (200 i n. l bs.)
Generator Mounting (4.0L)
Bol ts . . . . . . . . . . . . . . . . . . . . . . 57 Nm (42 ft. l bs.)
Radiator Upper Isolator to Crossmember
Nuts . . . . . . . . . . . . . . . . . . . . . . . 3 Nm (20 i n. l bs.)
Radiator Upper Isolator to Radiator
Nuts . . . . . . . . . . . . . . . . . . . . . . . 4 Nm (36 i n. l bs.)
Radiator Brace
Bol ts . . . . . . . . . . . . . . . . . . . . . 10 Nm (90 i n. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft. l bs.)
Transmission Auxiliary Oil Cooler
Bol ts . . . . . . . . . . . . . . . . . . . . . 10 Nm (90 i n. l bs.)
Upper Radiator Crossmember to Body
Bol ts . . . . . . . . . . . . . . . . . . . . . 10 Nm (90 i n. l bs.)
Water Pump (4.0L)
Bol ts . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft. l bs.)
Water Pump (5.2/5.9L)
Bol ts . . . . . . . . . . . . . . . . . . . . . . 40 Nm (30 ft. l bs.)
Water Pump Pulley (5.2/5.9L)
Bol ts . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
SPECIAL TOOLS
SPECIAL TOOLS COOLING
Pliers 6094
Pressure Tester 7700A
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 2
COOLANT TANK . . . . . . . . . . . . . . . . . . . . . . . . 2
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOW COOLANT LEVEL SENSOR . . . . . . . . . . . 4
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . 4
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . 5
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . 6
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . 6
AUTOMATIC BELT TENSIONER . . . . . . . . . . . . . 7
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRESSURE/VENT CAP . . . . . . . . . . . . . . . . . . . 4
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . 7
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 13
RADIATOR COOLANT FLOW CHECK . . . . . . . 13
TESTING COOLING SYSTEM FOR LEAKS . . . 14
LOW COOLANT LEVEL- AERATION . . . . . . . . . 15
BELT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 15
SERVICE PROCEDURES
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . 17
DRAINING COOLING SYSTEM . . . . . . . . . . . . 17
REFILLING COOLING SYSTEM . . . . . . . . . . . . 17
COOLANT REPLACEMENT . . . . . . . . . . . . . . . 18
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FAN BLADE REMOVAL . . . . . . . . . . . . . . . . . . 19
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 21
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AUTOMATIC BELT TENSIONER . . . . . . . . . . . . 22
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 22
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 24
RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . 24
FAN BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
COOLING SYSTEM CLEANING/REVERSE
FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ADJUSTMENTS
DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS
COOLING SYSTEM CAPACITY . . . . . . . . . . . . 26
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 26
GENERAL INFORMATION
COOLING SYSTEM
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e, mai ntai ns
normal operati ng temperature and prevents over-
heati ng.
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment. The cool i ng system
i s pressuri zed and uses a centri fugal water pump to
ci rcul ate cool ant throughout the system. A water
mani fol d col l ects cool ant from the cyl i nder heads. A
separate and remotel y mounted, pressuri zed cool ant
tank usi ng a pressure/vent cap i s used.
COOLING SYSTEM COMPONENTS
The cool i ng system consi sts of:
A brass-core radi ator wi th pl asti c si de tanks
A radi ator mounted fi l l vent val ve
A separate pressuri zed cool ant tank
A cam type pressure/vent cap mounted to the
cool ant tank
Cool i ng fan (mechani cal )
Thermal vi scous fan dri ve
Fan shroud
Thermostat
Cool ant
Low cool ant l evel sensor
Low cool ant warni ng l amp
Cool ant temperature gauge
Water pump
Hoses and hose cl amps
COOLANT ROUTING
For cool i ng system fl ow routi ng, refer to (Fi g. 1)
RADIATOR
The radi ator used wi th the 2.5L di esel i s con-
structed of a hori zontal cross-fl ow brass core wi th
pl asti c si de tanks.
CAUTION: Plastic tanks, while stronger than brass,
are subject to damage by impact, such as
wrenches.
I f the pl asti c tank has been damaged, the tank
and/or gaskets are avai l abl e for servi ce repai r. Tank
repl acement shoul d be done by qual i fi ed personal
wi th proper equi pment.
ENGINE ACCESSORY DRIVE BELTS
The accessory dri ve components are operated by a
si ngl e, crankshaft dri ven, serpenti ne dri ve bel t. I ni -
ti al bel t adjustment i s done wi th an adjustabl e ten-
si oner pul l ey. After the i ni ti al adjustment i s
performed, an automati c bel t tensi oner i s used to
mai ntai n correct bel t tensi on at al l ti mes.
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to water pump rotat-
ing in wrong direction. Refer to the engine Belt
Schematic in Specification section at the end of this
group for the correct belt routing.
COOLANT TANK
A pressuri zed, pl asti c cool ant tank i s used wi th the
cool i ng system. Thi s separate tank shoul d be consi d-
ered part of the radi ator. The tank i s l ocated at the
ri ght-rear si de of the engi ne compartment and i s
mounted as the hi ghest poi nt of the cool i ng system.
Thi s wi l l al l ow any ai r or vapor exceedi ng the pres-
sure/vent cap rati ng to escape through the cap. Cool -
ant wi l l fl ow through the tank at al l ti mes duri ng
engi ne operati on whether the engi ne i s col d or at
Fig. 1 Coolant Flow2.5L Diesel EngineTypical
normal operati ng temperature. The cool ant tank i s
equi pped wi th a cam type pressure/vent cap. Refer to
Pressure/Vent Cap for addi ti onal i nformati on.
A separate cool ant reserve/overfl ow tank i s not
used wi th thi s system.
The l ow cool ant l evel sensor i s l ocated on the bot-
tom of the tank (Fi g. 2).
WATER PUMP
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, water mani fol d,
radi ator core, pressuri zed cool ant tank, cool i ng sys-
tem hoses and heater core. The pump i s dri ven from
the engi ne crankshaft by a dri ve bel t. The water
pump i s bol ted to the water pump adapter (Fi g. 3).
The water pump adapter i s bol ted to the engi ne.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The bottom of the housi ng i s equi pped wi th
a smal l vent tube (Fi g. 3) to al l ow seepage to escape.
A drai n hose i s attached to thi s tube. The water
pump seal s are l ubri cated by the anti freeze i n the
cool ant mi xture. No addi ti onal l ubri cati on i s neces-
sary.
A rubber o-ri ng (i nstead of a gasket) i s used as a
seal between the water pump and the water pump
adapter (Fi g. 3).
Fig. 2 Coolant Tank and Radiator Hoses
Fig. 3 Water Pump Typical
A qui ck test to determi ne i f the pump i s worki ng i s
to check i f the heater warms properl y. A defecti ve
water pump wi l l not be abl e to ci rcul ate heated cool -
ant through the l ong heater hose to the heater core.
COOLANT
The cool i ng system i s desi gned around the cool ant.
Cool ant fl ows through the engi ne water jackets and
water mani fol d absorbi ng heat produced duri ng
engi ne operati on. The cool ant carri es heat to the
radi ator and heater core. Here i t i s transferred to the
ambi ent ai r passi ng through the radi ator and heater
core fi ns.
LOW COOLANT LEVEL SENSOR
The l ow cool ant l evel sensor checks for l ow cool ant
l evel i n the cool ant tank. A si gnal wi l l be sent from
thi s sensor to the powertrai n control modul e (PCM).
When the PCM determi nes l ow cool ant l evel , the
i nstrument panel mounted l ow cool ant l evel warni ng
l amp wi l l be i l l umi nated. The sensor i s l ocated on the
bottom of the cool ant tank. For i nformati on, refer to
Group 8E, I nstrument Panel and Gauges.
I f thi s l amp i s i l l umi nated, i t i ndi cates the need for
servi ce.
THERMOSTAT
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. The thermostat starts
to open at 80C (176F). Above thi s temperature,
cool ant i s al l owed to fl ow to the radi ator. Thi s pro-
vi des qui ck engi ne warmup and overal l temperature
control .
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warmup ti me, unrel i -
abl e warmup performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
CAUTION: Do not operate an engine without a
thermostat, except for servicing or testing.
PRESSURE/VENT CAP
The pressure/vent cap i s cam type cap. Thi s cap
rel eases excess pressure at some poi nt wi thi n a
range of 90 - 117 kPa (13 - 17 psi ). The actual pres-
sure rel i ef poi nt (i n pounds) i s l abel ed on top of the
cap.
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap contai ns a spri ng-
l oaded pressure rel i ef val ve. Thi s val ve opens when
system pressure reaches approxi matel y 103 kPa (15
psi ).
When the engi ne i s cool i ng down, vacuum i s
formed wi thi n the cool i ng system. To prevent col l apse
of the radi ator and cool ant hoses from thi s vacuum, a
vacuum val ve i s used wi thi n the cap. Thi s val ve pre-
vents excessi ve pressure di fferences from occurri ng
between the cl osed cool i ng system and the atmo-
sphere. I f the vacuum val ve i s stuck shut, the radi a-
tor and/or cool i ng system hoses wi l l col l apse on cool -
down.
NOTE: Do not use any type of tool when tighten-
ing the cap. Hand tighten only (approximately 5 Nm
or 44 in. lbs.) torque.
COOLANT PERFORMANCE
ETHYLENE-GLYCOL MIXTURES
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon the cl i mate and vehi cl e oper-
ati ng condi ti ons. The recommended mi xture of 50/50
ethyl ene-gl ycol and water wi l l provi de protecti on
agai nst freezi ng to -37 deg. C (-35 deg. F). The anti -
freeze concentrati on must always be a mi ni mum of
44 percent, year-round i n al l cl i mates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maxi mum protecti on agai nst freezi ng i s provi ded
wi th a 68 percent anti freeze concentrati on, whi ch
prevents freezi ng down to -67.7 deg. C (-90 deg. F). A
hi gher percentage wi l l freeze at a warmer tempera-
ture. Al so, a hi gher percentage of anti freeze can
cause the engi ne to overheat because the speci fi c
heat of anti freeze i s l ower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used in
Chrysler Vehicles
Use of 100 percent ethyl ene-gl ycol wi l l cause for-
mati on of addi ti ve deposi ts i n the system, as the cor-
rosi on i nhi bi ti ve addi ti ves i n ethyl ene-gl ycol requi re
the presence of water to di ssol ve. The deposi ts act as
i nsul ati on, causi ng temperatures to ri se to as hi gh as
149 deg. C (300) deg. F). Thi s temperature i s hot
enough to mel t pl asti c and soften sol der. The
i ncreased temperature can resul t i n engi ne detona-
ti on. I n addi ti on, 100 percent ethyl ene-gl ycol freezes
at 22 deg. C (-8 deg. F ).
Propylene-glycol Formulations Should Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications. I ts overal l effec-
ti ve temperature range i s smal l er than that of ethyl -
ene-gl ycol . The freeze poi nt of 50/50 propyl ene-gl ycol
and water i s -32 deg. C (-26 deg. F). 5 deg. C hi gher
than ethyl ene-gl ycol s freeze poi nt. The boi l i ng poi nt
(protecti on agai nst summer boi l -over) of propyl ene-
gl ycol i s 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi ),
compared to 128 deg. C (263 deg. F) for ethyl ene-gl y-
col . Use of propyl ene-gl ycol can resul t i n boi l -over or
freeze-up i n Chrysl er vehi cl es, whi ch are desi gned for
ethyl ene-gl ycol . Propyl ene gl ycol al so has poorer heat
transfer characteri sti cs than ethyl ene gl ycol . Thi s
can i ncrease cyl i nder head temperatures under cer-
tai n condi ti ons.
Propylene-glycol/Ethylene-glycol Mixtures Should Not Be
Used in Chrysler Vehicles
Propyl ene-gl ycol /ethyl ene-gl ycol Mi xtures can
cause the destabi l i zati on of vari ous corrosi on i nhi bi -
tors, causi ng damage to the vari ous cool i ng system
components. Al so, once ethyl ene-gl ycol and propy-
l ene-gl ycol based cool ants are mi xed i n the vehi cl e,
conventi onal methods of determi ni ng freeze poi nt wi l l
not be accurate. Both the refracti ve i ndex and spe-
ci fi c gravi ty di ffer between ethyl ene gl ycol and propy-
l ene gl ycol .
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLING SYSTEM HOSES
Rubber hoses route cool ant to and from the radi a-
tor, water mani fol d and heater core. Model s equi pped
wi th ai r condi ti oni ng have a heater water control
(shut-off) val ve. Thi s i s l ocated i n-l i ne wi th the
heater core i nl et and outl et hoses. I t control s cool ant
fl ow to the heater core when the ai r condi ti oni ng sys-
tem i s i n operati on.
Radi ator l ower hoses are spri ng-rei nforced to pre-
vent col l apse from water pump sucti on at moderate
and hi gh engi ne speeds.
CLAMP (Fig. 4). ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.
I nspect the hoses at regul ar i nterval s. Repl ace
hoses that are cracked, feel bri ttl e when squeezed, or
swel l excessi vel y when the system i s pressuri zed.
For al l vehi cl es: I n areas where speci fi c routi ng
cl amps are not provi ded, be sure that hoses are posi -
ti oned wi th suffi ci ent cl earance. Check cl earance
from exhaust mani fol ds and pi pe, fan bl ades, dri ve
bel ts and sway bars. I mproperl y posi ti oned hoses can
be damaged, resul ti ng i n cool ant l oss and engi ne
overheati ng.
Fig. 4 Hose Clamp Tool
Ordi nary worm gear type hose cl amps (when
equi pped) can be removed wi th a strai ght screw-
dri ver or a hex socket. To prevent damage to
hoses or clamps, the hose clamps should be
tightened to 4 Nm (34 in. lbs.) torque. Do not
over tighten hose clamps.
When performi ng a hose i nspecti on, i nspect the
radi ator l ower hose for proper posi ti on and condi ti on
of the i nternal spri ng.
VISCOUS FAN DRIVE
The thermal vi scous fan dri ve (Fi g. 6) i s a si l i cone-
fl ui d-fi l l ed coupl i ng. I t connects the fan bl ade assem-
bl y to the fan pul l ey. The coupl i ng al l ows the fan to
be dri ven i n a normal manner. Thi s i s done at l ow
engi ne speeds whi l e l i mi ti ng the top speed of the fan
to a predetermi ned maxi mum l evel at hi gher engi ne
speeds. A bi metal l i c spri ng coi l i s l ocated on the front
face. Thi s spri ng coi l reacts to the temperature of the
radi ator di scharge ai r. I t engages the vi scous fan
dri ve for hi gher fan speed i f the ai r temperature from
the radi ator ri ses above a certai n poi nt. Unti l addi -
ti onal engi ne cool i ng i s necessary, the fan wi l l remai n
at a reduced rpm regardl ess of engi ne speed.
The vi scous fan dri ve wi l l onl y engage when suffi -
ci ent heat i s present. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on from the
di sengaged speed.
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
NOISE
ing) when:
hi gh.
engi ne.
LEAKS
BELT TENSION
Correct accessory dri ve bel t tensi on i s requi red to
be sure of opti mum performance of bel t dri ven engi ne
accessori es. I f speci fi ed tensi on i s not mai ntai ned,
bel t sl i ppage may cause; engi ne overheati ng, l ack of
power steeri ng assi st, l oss of ai r condi ti oni ng capac-
i ty, reduced generator output rate and greatl y
reduced bel t l i fe.
I ni ti al bel t adjustment i s done wi th a adjustabl e
tensi oner pul l ey. After the i ni ti al adjustment i s per-
formed, an automati c bel t tensi oner i s used to mai n-
tai n correct bel t tensi on at al l ti mes. Do not attempt
to check bel t tensi on wi th a bel t tensi on gauge on
vehi cl es equi pped wi th an automati c bel t tensi oner.
Refer to Automati c Bel t Tensi oner i n thi s group.
Fig. 6 Viscous Fan Drive
Dri ve bel t tensi on i s control l ed by a spri ng l oaded
automati c bel t tensi oner l ocated bel ow and to the
front of the engi ne oi l fi l ter (Fi g. 7). Thi s tensi oner i s
connected to a pi vot bracket and a pul l ey (Fi g. 7).
The pi vot bracket rotates on a pi vot pi n attached to
the engi ne. Speci al machi ned washers wi th rubber
o-ri ngs (Fi g. 7) are used at each si de of the pi vot
bracket to hel p keep di rt and water away from the
pi vot pi n.
I f a defecti ve bel t tensi oner i s suspected, a check of
thi s pi vot bracket and pi vot pi n shoul d be made. Cor-
rosi on may have formed at the pi n and may cause
the pi vot bracket to sti ck. Bel t sl i ppage wi l l resul t.
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE THE
AUTOMATIC BELT TENSIONER. UNIT IS SERVICED
AS AN ASSEMBLY.
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
(1) PROLONGED I DLE, VERY HI GH AMBI ENT
TEMPERATURE, SLI GHT TAI L WI ND AT I DLE,
SLOW TRAFFI C, TRAFFI C JAMS, HI GH SPEED
OR STEEP GRADES.
Dri vi ng techni ques that avoi d overheati ng are:
I dl e wi th A/C off when temperature gauge i s at
end of normal range.
I ncreasi ng engi ne speed for more ai r fl ow i s rec-
ommended.
(2) TRAI LER TOWI NG:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
(3) RECENT SERVI CE OR ACCI DENT REPAI R:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
Engi ne adjustments (i ncorrect ti mi ng)
Sl i ppi ng engi ne accessory dri ve bel t
Brakes (possi bl y draggi ng)
Changed parts (i ncorrect water pump)
Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a qui ck-reference
onl y. Refer to the group text for i nformati on.
Fig. 7 Automatic Belt Tensioner Assembly
COOLING SYSTEM DIAGNOSISDIESEL ENGINE
THERMOSTAT
DIAGNOSIS
Di esel engi nes, due to thei r i nherent effi ci ency are
sl ower to warm up than gasol i ne powered engi nes,
and wi l l operate at l ower temperatures when the
vehi cl e i s unl oaded. Because of thi s, l ower tempera-
ture gauge readi ngs for di esel versus gasol i ne
engi nes may, at ti mes be normal .
Typi cal l y, compl ai nts of l ow engi ne cool ant temper-
ature are observed as l ow heater output when com-
bi ned wi th cool or col d outsi de temperatures.
To hel p promote faster engi ne warm-up, an el ectri c
engi ne bl ock heater must be used wi th cool or col d
outsi de temperatures. Thi s wi l l hel p keep the engi ne
cool ant warm when the vehi cl e i s parked. Use the
bl ock heater i f the outsi de temperature i s bel ow 4C
(40F). Do not use the block heater if the out-
side temperature is above 4C (40F).
TESTING
NOTE: The DRB scan tool cannot be used to mon-
itor engine coolant temperature on the diesel
engine.
(1) To determi ne i f the thermostat i s defecti ve, i t
must be removed from the vehi cl e. Refer to Thermo-
stats for removal and i nstal l ati on procedures.
(2) After the thermostat has been removed, exam-
i ne the thermostat and i nsi de of thermostat housi ng
for contami nants. I f contami nants are found, the
thermostat may al ready be i n a stuck open posi ti on.
Fl ush the cool i ng system before repl aci ng thermostat.
Refer to Cool i ng System Cl eani ng/Reverse Fl ushi ng
i n thi s group for addi ti onal i nformati on.
(3) Pl ace the thermostat i nto a contai ner fi l l ed
wi th water.
(4) Pl ace the contai ner on a hot pl ate or other sui t-
abl e heati ng devi ce.
(5) Pl ace a commerci al l y avai l abl e radi ator ther-
mometer i nto the water.
(6) Appl y heat to the water whi l e observi ng the
thermostat and thermometer.
(7) When the water temperature reaches 80C
(176F) the thermostat shoul d start to open (val ve
wi l l start to move). I f the val ve starts to move before
thi s temperature i s reached, i t i s openi ng too earl y.
Repl ace thermostat. The thermostat shoul d be ful l y
open (val ve wi l l stop movi ng) at approxi matel y 89C
(192F). I f the val ve i s sti l l movi ng after the water
temperature reaches thi s temperature, i t i s openi ng
too l ate. Repl ace thermostat.
(8) I f the val ve refuses to move at any ti me,
repl ace thermostat.
VISCOUS FAN DRIVE
TESTING
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
The cool i ng system must be i n good condi ti on. Thi s
i s checked pri or to performi ng the fol l owi ng test. I t
al so wi l l ensure agai nst excessi vel y hi gh cool ant tem-
perature.
WARNING: BE SURE OF ADEQUATE FAN BLADE
CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.12-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18-to-
105C (0-to-220 F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(4) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
(5) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 93 C (200 F).
Fan dri ve engagement shoul d have started to occur
at between 82 to 91 C (180 to 195 F). Engage-
ment i s di sti ngui shabl e by a defi ni te increase i n fan
fl ow noi se (roari ng).
(6) When the ai r temperature reaches 93 C (200
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 57 to
79 C (135 to 175 F). A defi ni te decrease of fan
fl ow noi se (roari ng) shoul d be noti ced. I f not, repl ace
the defecti ve vi scous fan dri ve uni t.
RADIATOR COOLANT FLOW CHECK
There i s cool ant fl ow al l of the ti me through the
cool ant tank (bottl e) before and after the thermostat
opens. I f you remove the vent val ve and i nsert a tem-
perature gauge through the openi ng, cool ant wi l l spi l l
out of the system and the engi ne wi l l not be fi l l ed
wi th cool ant up to the heads.
CAUTION: Major damage could happen if you run
the engine in this condition.
TESTING COOLING SYSTEM FOR LEAKS
ULTRAVIOLET LIGHT METHOD
Al l Jeep model s have a l eak detecti on addi ti ve
added to the cool i ng system before they l eave the fac-
tory. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). I f the factory ori gi nal cool ant has
been drai ned, pour one ounce of addi ti ve i nto the
cool i ng system. The addi ti ve i s avai l abl e through the
parts department. Pl ace the heater control uni t i n
HEAT posi ti on. Start and operate the engi ne unti l
the radi ator upper hose i s warm to the touch. Ai m
the commerci al l y avai l abl e bl ack l i ght tool at the
components to be checked. I f l eaks are present, the
bl ack l i ght wi l l cause the addi ti ve to gl ow a bri ght
green col or.
The bl ack l i ght can be used al ong wi th a radi ator
pressure tester to determi ne i f any external l eaks
exi st (Fi g. 9).
PRESSURE TESTER METHOD
CAUSE INJURY BY SCALDING. NEVER REMOVE
THE PRESSURE/VENT CAP OR PRESSURE TESTER
WHEN THE COOLING SYSTEM IS HOT OR UNDER
PRESSURE!
Al l ow the engi ne to cool suffi ci entl y so that the
system i s not under pressure and careful l y remove
the pressure/vent cap from the fi l l er neck. Warm the
engi ne wi th the pressure/vent cap off to normal oper-
ati ng temperature. Wi th the engi ne turned off attach
the cool i ng system pressure tester and test the sys-
tem as descri bed bel ow.
Recheck the system col d i f the cause of cool ant l oss
i s not l ocated duri ng warm engi ne exami nati on.
Operate the tester pump to appl y 103 kPa (15 psi )
pressure to the system. I f the hoses enl arge exces-
si vel y or bul ge whi l e testi ng, repl ace as necessary.
Observe the gauge poi nter and determi ne the condi -
ti on of the cool i ng system accordi ng to the fol l owi ng
cri teri a:
Hol ds Steady: I f the poi nter remai ns steady for
two mi nutes, there are no seri ous cool ant l eaks i n
the system. However, there coul d be an i nternal l eak
that does not appear wi th normal system test pres-
sure. I nspect for i nteri or l eakage or do the I nternal
Leakage Test. Do thi s i f i t i s certai n that cool ant i s
bei ng l ost and no l eaks can be detected.
Drops Sl owl y: Shows a smal l l eak or seepage i s
occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect the radi ator,
hoses, gasket edges and heater. Seal any smal l l eak
hol es wi th a Seal er Lubri cant or equi val ent. Repai r
l eak hol es and rei nspect the system wi th pressure
appl i ed.
Drops Qui ckl y: Shows that a seri ous l eakage i s
occurri ng. Exami ne the system for seri ous external
l eakage. I f no l eaks are vi si bl e, i nspect for i nternal
l eakage. Large radi ator l eak hol es shoul d be repai red
by a reputabl e radi ator repai r shop.
Fig. 9 Leak Detection Using Black LightTypical
Fig. 10 Typical Cooling System Pressure Tester
INTERNAL LEAKAGE INSPECTION
Remove the oi l pan drai n-pl ug and drai n a smal l
amount of engi ne oi l . Cool ant, bei ng heavi er wi l l
drai n fi rst, or operate engi ne to churn oi l , then exam-
i ne di psti ck for water gl obul es. Operate the engi ne
wi thout the pressure/vent cap on the cool ant tank
unti l thermostat opens.
Attach a radi ator pressure tester to the tank fi l l er
neck. I f pressure bui l ds up qui ckl y, a l eak exi sts as
resul t of a faul ty cyl i nder head gasket or crack i n the
engi ne. Repai r as necessary.
WARNING: DO NOT ALLOW PRESSURE TO
EXCEED 117 KPA (17 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.
I f there i s no i mmedi ate pressure i ncrease, pump
the pressure tester unti l the i ndi cated pressure i s
wi thi n the system range. Vi brati on of the gauge
poi nter i ndi cates compressi on or combusti on l eakage
i nto the cool i ng system.
LOW COOLANT LEVEL- AERATION
CAUTION: Engine damage could occur if the cool-
ant level is allowed to get this low. Always ensure
that the coolant level is not below the add coolant
mark. The baffles in the pressurized coolant tank
(degasser bottle) will not allow you to see the fluid
level. Check the coolant level through the pressur-
ized coolant tank. For better visibility of the coolant
level use a shop lamp to light the pressurized cool-
ant tank and look through the pressurized coolant
tank.
I f the cool ant l evel i n the radi ator drops bel ow the
top of radi ator core tubes, ai r wi l l enter the cool i ng
system.
Low cool ant l evel can cause the thermostat pel l et
to be suspended i n ai r i nstead of cool ant. Thi s wi l l
cause the thermostat to open l ater, whi ch i n turn
causes hi gher cool ant temperature. Ai r trapped i n
the cool i ng system al so reduces the amount of cool ant
ci rcul ati ng i n the heater core resul ti ng i n l ow heat
output.
BELT DIAGNOSIS
When di agnosi ng serpenti ne accessory dri ve bel ts,
smal l cracks that run across the ri bbed surface of the
bel t from ri b to ri b (Fi g. 11), are consi dered normal .
These are not a reason to repl ace the bel t. However,
cracks runni ng al ong a ri b (not across) are not nor-
mal . Any bel t wi th cracks runni ng al ong a ri b must
be repl aced (Fi g. 11). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
Refer to the Serpenti ne Dri ve Bel t Di agnosi s chart
for further bel t di agnosi s.
Fig. 11 Serpentine Belt Wear Patterns
SERPENTINE DRIVE BELT DIAGNOSIS
SERVICE PROCEDURES
COOLANT LEVEL CHECK
The cool ant l evel i s checked and adjusted at the
pressuri zed cool ant tank. The tank i s l ocated at the
ri ght-rear si de of the engi ne compartment and i s
mounted as the hi ghest poi nt of the cool i ng system.
Thi s wi l l al l ow any ai r or vapor exceedi ng the pres-
sure/vent cap rati ng to escape through the cap. The
cool ant tank i s equi pped wi th a cam type pressure/
vent cap. Refer to Pressure/Vent Cap for addi ti onal
i nformati on.
A cool ant reserve/overfl ow system wi th a separate
tank i s not used wi th the 2.5L di esel engi ne.
(1) Add cool ant i nto the cool ant tank up to the
COLD mark. If possible, only add coolant when
the engine is cold. Coolant level in a warm
engine will be higher in the tank due to ther-
mal expansion.
(2) After the engi ne has been operated through a
few heat-up and cool -down cycl es, recheck the cool ant
l evel i n the tank.
DRAINING COOLING SYSTEM
The cool i ng system i s equi pped wi th a pressuri zed
cool ant tank usi ng a pressure/vent cap.
BLOCK DRAIN-PLUG, THE COOLANT TANK CAP,
THE RADIATOR FILL VENT VALVE, OR LOOSEN
THE RADIATOR DRAINCOCK WITH THE SYSTEM
HOT AND PRESSURIZED. SERIOUS BURNS FROM
THE COOLANT CAN OCCUR.
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE
REMOVING COOLANT TANK CAP. WITH A RAG,
SQUEEZE THE UPPER RADIATOR HOSE TO CHECK
IF SYSTEM IS UNDER PRESSURE. PLACE A RAG
OVER THE CAP. VERY SLOWLY ROTATE THE CAP
COUNTERCLOCKWISE ALLOWING PRESSURE TO
SLOWLY RELEASE. AFTER ALL PRESSURE HAS
BEEN RELEASED, REMOVE THE COOLANT TANK
CAP COMPLETELY.
reuse.
(1) Observe the previ ous WARNINGS and remove
the cool ant tank pressure/vent cap.
(2) The pl asti c radi ator drai ncock i s l ocated on the
bottom of the l eft radi ator tank. I t can be accessed
from the bottom of vehi cl e.
(a) Attach one end of a 24 i nch l ong X 1/4 i nch
I D drai n-hose to the ni ppl e bel ow the radi ator
drai ncock.
(b) Put the other end of drai n-hose i nto a cl ean
contai ner.
(c) Open the drai ncock (countercl ockwi se as
vi ewed from l eft si de of vehi cl e) and drai n cool ant
from radi ator.
(3) I f the compl ete cool i ng system must be drai ned,
rai se the vehi cl e and remove the cyl i nder bl ock
drai n-pl ug (Fi g. 12). Thi s hex- headed pl ug i s l ocated
on the ri ght/rear si de of the engi ne above the starter
motor.
REFILLING COOLING SYSTEM
The cool i ng system i s equi pped wi th a pressuri zed
cool ant tank usi ng a pressure/vent cap. Refi l l i ng of
the system i s done through thi s tank.
NOTE: The radiator draincock is equipped with a
rubber o-ring. Do not over tighten draincock.
Fig. 12 Cylinder Block Drain-Plug
(1) Ti ghten the radi ator drai ncock and (i f
removed), the cyl i nder bl ock drai n-pl ug.
(2) Remove the pl asti c radi ator fi l l vent val ve
(unscrews countercl ockwi se) from the radi ator. The
fi l l vent val ve i s l ocated on the top of the ri ght radi -
ator tank (Fi g. 13).
(3) Wi th the fi l l vent val ve removed, proceed to fi l l
the system usi ng a 50/50 mi xture of water and anti -
freeze as descri bed i n the Cool ant secti on of thi s
group.
(4) Conti nue to fi l l the cool i ng system unti l cool ant
i s observed escapi ng from the fi l l vent openi ng. When
thi s occurs, i nstal l the fi l l vent val ve. The plastic
fill vent valve is equipped with a rubber o-
ring. Do not over tighten the fill vent valve.
(5) Conti nue to fi l l the system unti l the cool ant
tank i s ful l .
(6) I nstal l and ti ghten the cool ant tank pressure/
vent cap. Do not use any type of tool when tight-
ening the cap. Hand tighten only.
(7) Wi th the heater control uni t i n the HEAT posi -
ti on, operate engi ne wi th cool ant tank cap ti ghtened.
(8) After engi ne has reached normal operati ng
temperature, shut engi ne off and al l ow i t to cool .
(9) Remove cool ant tank cap.
(10) Add cool ant i nto the cool ant tank up to the
COLD mark. If possible, only add coolant when
the engine is cold. Coolant level in a warm
engine will be higher in the tank due to ther-
mal expansion.
(11) After the engi ne has been operated through a
few heat-up and cool -down cycl es, recheck the cool ant
l evel i n the tank.
COOLANT REPLACEMENT
I t i s recommended that the cool i ng system be
drai ned and fl ushed at 84,000 ki l ometers (52,500
mi l es), or 3 years, whi chever occurs fi rst. Then every
two years, or 48,000 ki l ometers (30,000 mi l es),
whi chever occurs fi rst.
RADIATOR
CLAMP (Fig. 14). ALWAYS WEAR SAFETY
GLASSES WHEN SERVICING CONSTANT TENSION
CLAMPS.
Fig. 13 Radiator Fill Vent Valve
REMOVAL
(2) Observe the previ ous WARNINGS.
(3) Drai n cool i ng system. Refer to Drai ni ng Cool -
(4) Remove the upper fan shroud-to-upper cross-
member mounti ng bol ts. One of the bol ts i s mounted
verti cal l y at the bottom of the fan shroud.
(5) Li ft the fan shroud up unti l al i gnment tabs at
the bottom are cl ear of sl ots i n bracket at bottom of
radi ator. Sl i p the fan shroud rearward and posi ti on i t
over the fan bl ades.
(6) Remove radi ator hose cl amps and remove radi -
ator hoses.
(7) Mark the posi ti on of the hood l atch stri ker on
the radi ator crossmember and remove hood l atch
stri ker.
(8) Remove radi ator upper crossmember.
(9) I f equi pped wi th ai r condi ti oni ng, separate the
radi ator from the A/C condenser by removi ng the
condenser-to-radi ator mounti ng brackets.
(10) Li ft radi ator strai ght up and out of engi ne
compartment taki ng care not to damage radi ator or
A/C condenser fi ns.
INSTALLATION
The radi ator i s equi pped wi th two al i gnment dow-
el s (Fi g. 16). They are l ocated on the bottom of the
pl asti c si de tanks and fi t i nto rubber grommets
l ocated i n the front l ower crossmember.
(1) Careful l y l ower the radi ator i nto engi ne com-
partment. Posi ti on the al i gnment dowel s on the bot-
tom of radi ator i nto the rubber grommets i n front
l ower crossmember (Fi g. 16).
(2) I f equi pped wi th ai r condi ti oni ng, attach con-
denser to radi ator wi th mounti ng brackets.
(3) I nstal l radi ator upper crossmember.
(4) I nstal l hood l atch stri ker.
(5) Connect radi ator upper and l ower hoses.
(6) I nsert al i gnment tabs at bottom of fan shroud
i nto sl ots i n bracket at bottom of radi ator. I nstal l and
ti ghten fan shroud bol ts to 3 Nm (31 i n. l bs.) torque.
(8) Fi l l cool i ng system wi th correct cool ant. Refer
to Refi l l i ng Cool i ng System i n thi s group.
(9) Start and warm the engi ne. Check for cool ant
l eaks.
FAN BLADE REMOVAL
FAN BLADE REMOVAL
Accessory dri ve bel t removal i s not necessary for
fan bl ade or vi scous fan dri ve removal .
(2) The thermal vi scous fan dri ve/fan bl ade assem-
bl y i s attached (threaded) to the fan pul l ey shaft
(Fi g. 17). Remove fan bl ade/vi scous fan dri ve assem-
bl y from fan pul l ey by turni ng mounti ng nut counter-
cl ockwi se as vi ewed from front. Threads on vi scous
fan dri ve are RIGHT HAND. Snap-On 36 MM Fan
Wrenches (number SP346) can be used to turn the
mounti ng nut and to hol d the fan pul l ey from rotat-
i ng.
Fig. 16 Radiator Alignment DowelsTypical
(4) Do not unbol t fan bl ade assembl y from vi scous
fan dri ve at thi s ti me.
(5) Remove the fan shroud mounti ng bol ts. One of
the bol ts i s mounted verti cal l y at the bottom of
shroud.
dri ve assembl y as a compl ete uni t from vehi cl e.
assembl y, do not pl ace vi scous fan dri ve i n hori zon-
tal posi ti on. I f stored hori zontal l y, si l i cone fl ui d i n
the vi scous fan dri ve coul d drai n i nto i ts beari ng
CAUTION: Do not attempt to remove the fan pulley
bolts. The fan pulley is under tension from the drive
belt.
(8) Remove four bol ts securi ng fan bl ade assembl y
to vi scous fan dri ve (Fi g. 17).
FAN BLADE INSTALLATION
(1) I nstal l fan bl ade assembl y to vi scous fan dri ve.
Ti ghten bol ts (Fi g. 17) to 23 Nm (200 i n. l bs.) torque.
(3) I nstal l and ti ghten fan shroud bol ts to 3 Nm
(31 i n. l bs.) torque.
fan pul l ey shaft (Fi g. 17).
VISCOUS FAN DRIVE
The thermal vi scous fan dri ve (Fi g. 18) i s a si l i -
cone-fl ui d-fi l l ed coupl i ng. I t connects the fan bl ade
assembl y to the fan pul l ey. The coupl i ng al l ows the
fan to be dri ven i n a normal manner. Thi s i s done at
l ow engi ne speeds whi l e l i mi ti ng the top speed of the
fan to a predetermi ned maxi mum l evel at hi gher
engi ne speeds. A bi metal l i c spri ng coi l i s l ocated on
the front face. Thi s spri ng coi l reacts to the temper-
ature of the radi ator di scharge ai r. I t engages the
vi scous fan dri ve for hi gher fan speed i f the ai r tem-
perature from the radi ator ri ses above a certai n
poi nt. Unti l addi ti onal engi ne cool i ng i s necessary,
the fan wi l l remai n at a reduced rpm regardl ess of
engi ne speed.
The vi scous fan dri ve wi l l onl y engage when suffi -
ci ent heat i s present. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on from the
di sengaged speed.
engine overheating.
NOISE
ing) when:
Fig. 17 Thermal Viscous Fan Drive and Blade
Assembly
Fig. 18 Viscous Fan Drive
hi gh.
engi ne.
LEAKS
THERMOSTAT
REMOVAL
reuse.
(1) Drai n the cool ant from the radi ator unti l the
l evel i s bel ow the thermostat housi ng. Refer to
Drai ni ng Cool i ng System for procedures.
CLAMPS.
(2) Remove the upper radi ator hose at the thermo-
stat housi ng.
(3) Remove the four thermostat housi ng bol ts (Fi g.
19)
(4) Remove the thermostat housi ng from the water
mani fol d.
(5) Remove the thermostat and rubber seal from
the water mani fol d.
(6) Thoroughl y cl ean the rubber seal mati ng sur-
faces.
INSTALLATION
(1) I nstal l a new rubber seal around the outer l i p
of the thermostat (a notch i s provi ded i n the rubber
seal ). Do not appl y any adhesi ve to thi s seal .
(2) I nstal l the repl acement thermostat and rubber
seal as one assembl y i nto the water mani fol d adapter
(the poi nted end of the thermostat shoul d be faci ng
towards the front of engi ne (Fi g. 19). Observe the
recess groove i n the water mani fol d adapter. Be sure
the thermostat vent i s i n the 12 ocl ock posi ti on (Fi g.
19).
(3) Posi ti on the thermostat housi ng and four bol ts
to the water mani fol d.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
groove, may result in a cracked housing.
(4) Ti ghten the four housi ng bol ts to 11 Nm (98
i n. l bs.) torque.
(5) I nstal l radi ator hose to thermostat housi ng.
(6) Be sure that the radi ator drai n i s ti ghtl y
cl osed. Fi l l the cool i ng system to the correct l evel
wi th the requi red cool ant mi xture. Refer to Refi l l i ng
Cool i ng System i n thi s group for procedures.
(7) Start and warm the engi ne. Check thermostat
and hose for l eaks.
Fig. 19 Thermostat Removal/Installation
DRIVE BELT
CAUTION: The drive belt on the 2.5L diesel engine
is equipped with a spring loaded automatic belt ten-
sioner. After belt installation, do not attempt to
check belt tension with a belt tension gauge.
WATER PUMP
REMOVAL
The water pump i s servi ced by repl aci ng the pump
and i ts i mpel l er onl y. The water pump adapter (Fi g.
21) does not have to be removed. The pump i mpel l er
i s pressed on the rear of the pump shaft and beari ng
assembl y. The pump i s servi ced onl y as a compl ete
assembl y wi th the i mpel l er, housi ng, hub and bear-
i ng.
A rubber o-ri ng seal (i nstead of a gasket) i s used as
a seal between the water pump and the water pump
adapter.
i s cl ean, drai n cool ant i nto a cl ean contai ner for
reuse.
(2) Drai n the cool i ng system. Refer to Drai ni ng
(3) The thermal vi scous fan dri ve and the fan
bl ade assembl y are attached (threaded) to the fan
pul l ey shaft (Fi g. 22). Remove the fan/fan dri ve
assembl y from the fan pul l ey by turni ng the mount-
i ng nut countercl ockwi se (as vi ewed from front).
Threads on the fan dri ve are RIGHT HAND. Snap-
On 36 MM Fan Wrenches (number SP346) can be
used to turn the mounti ng nut and to hol d the fan
pul l ey from rotati ng.
(4) I f the water pump i s bei ng repl aced, do not
unbol t the fan bl ade assembl y (Fi g. 22) from the
thermal vi scous fan dri ve.
(5) Remove the upper fan shroud-to-upper cross-
member mounti ng bol ts. One of the bol ts i s mounted
verti cal l y at the bottom of the fan shroud.
(6) Sl i p the fan shroud rearward. Remove the fan
shroud and vi scous dri ve/fan bl ade together as one
assembl y from the engi ne compartment.
(7) Loosen but do not remove the 3 water pump
pul l ey bol ts (Fi g. 21).
Fig. 20 Automatic Belt Tensioner Assembly
Fig. 21 WATER PUMP REMOVAL/INSTALL
TYPICAL
(8) Remove the dri ve bel t by removi ng the auto-
mati c bel t tensi oner. For procedures, refer to Bel t
Removal /I nstal l ati on i n the Engi ne Accessory Dri ve
Bel ts secti on of thi s group.
CLAMPS.
(9) A metal cool ant tube (used to connect rubber
cool ant hoses), and i ts mounti ng bracket are attached
to the front of the water pump (Fi g. 25). A rubber
hose connects thi s tube to the engi ne. Di sconnect the
hose cl amp and rubber hose at the back of the ther-
mostat. Posi ti on the hose to the si de.
(10) Remove the 3 water pump pul l ey bol ts (Fi g.
21).
(11) Remove the water pump pul l ey from the
water pump.
(12) Di sconnect the drai n hose from the vent tube
at the bottom of water pump (Fi g. 21).
(13) Remove the 4 water pump mounti ng bol ts
(Fi g. 21).
(14) Remove water pump from engi ne.
INSTALLATION
(1) Cl ean the o-ri ng mati ng surfaces. I f the ori gi -
nal pump i s to be rei nstal l ed, remove any deposi ts or
other forei gn materi al . I nspect the water pump,
water pump adapter and water pump mati ng sur-
faces for erosi on or damage from cavi tati on.
(2) Posi ti on a new rubber o-ri ng seal (Fi g. 21)
between the pump and pump adapter. Hol d the seal
wi th petrol eum jel l y.
(3) Posi ti on the pump to the engi ne.
Assembly
(4) Posi ti on the metal cool ant tube and i ts mount-
i ng bracket to the pump.
(5) I nstal l the four water pump mounti ng bol ts.
(6) I nstal l drai n hose to vent tube at bottom of
pump.
(7) Posi ti on the water pump pul l ey to the water
pump.
(8) I nstal l the water pump pul l ey bol ts fi nger
ti ght.
(9) I nstal l the rubber cool ant hose near the ther-
mostat.
(10) I nstal l the dri ve bel t and bel t tensi oner. For
procedures, refer to Bel t Removal /I nstal l ati on i n the
Engi ne Accessory Dri ve Bel ts secti on of thi s group.
(11) Ti ghten the water pump pul l ey bol ts to 24
(12) Posi ti on the vi scous dri ve/fan bl ade and fan
shroud to the engi ne compartment as one assembl y.
(13) I nstal l the thermal vi scous fan dri ve and fan
bl ade to fan pul l ey. Ti ghten to 56 Nm (41 ft. l bs.)
torque.
(14) I nstal l and ti ghten fan shroud mounti ng bol ts
to 3 Nm (31 i n. l bs.) torque.
(15) Fi l l cool i ng system wi th cool ant and check for
l eaks. Refer to Refi l l i ng Cool i ng System i n thi s
group.
WATER PUMP
INSPECTION
Repl ace the water pump assembl y i f i t has any of
the fol l owi ng condi ti ons:
The body i s cracked or damaged
Water l eaks from the shaft seal . Thi s i s evi dent
by traces of cool ant bel ow the vent tube drai n hose
Loose or rough turni ng beari ng.
I mpel l er rubs ei ther the water pump body or
water pump adapter.
RADIATOR CLEANING
The radi ator and ai r condi ti oni ng fi ns shoul d be
cl eaned when an accumul ati on of bugs, l eaves etc.
has occurred. Cl ean radi ator fi ns are necessary for
good heat transfer. Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
FAN BLADE
INSPECTION
The fan cannot be repai red. I f fan i s damaged, i t
must be repl aced. I nspect fan as fol l ows:
(1) Remove fan bl ade and vi scous fan dri ve as an
assembl y from the engi ne.
(2) Remove fan bl ade assembl y from vi scous fan
dri ve uni t (four bol ts) (Fi g. 26).
(3) Lay fan on a fl at surface wi th l eadi ng edge fac-
i ng down. Wi th ti p of bl ade touchi ng fl at surface,
repl ace fan i f cl earance between opposi te bl ade and
surface i s greater than 2.0 mm (.090 i nch). Rocki ng
Fig. 25 Coolant Tube at Water Pump
Assembly
moti on of opposi te bl ades shoul d not exceed 2.0 mm
(.090 i nch). Test al l bl ades i n thi s manner.
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI-
FICATIONS.
(4) I nspect fan assembl y for cracks, bends, l oose
ri vets or broken wel ds. Repl ace fan i f any damage i s
found.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, the fan pulley bear-
ing and viscous fan drive should also be inspected.
These components could have been damaged due
to excessive vibration.
engine overheating.
COOLING SYSTEM CLEANING/REVERSE FLUSHING
at 90-to-117 kPa (13- to-17 psi) pressure. Exceeding
CLEANING
Drai n cool i ng system and refi l l wi th water. Run
engi ne wi th cool ant tank pressure/vent cap i nstal l ed
unti l upper radi ator hose i s hot. Stop engi ne and
drai n water from system. I f water i s di rty, fi l l system
wi th water, run engi ne and drai n system. Repeat
unti l water drai ns cl ean.
REVERSE FLUSHING
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
at 90-to-117 kPa (13- to-17 psi) pressure. Exceeding
Al l ow the cool ant tank and radi ator to fi l l wi th
water. When radi ator i s fi l l ed, appl y ai r i n short
bl asts al l owi ng radi ator to refi l l between bl asts. Con-
ti nue thi s reverse fl ushi ng unti l cl ean water fl ows
out through rear of radi ator cool i ng tube passages.
For more i nformati on, refer to operati ng i nstructi ons
suppl i ed wi th fl ushi ng equi pment. Have radi ator
cl eaned more extensi vel y by a radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system. Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
CAUTION: Be sure that the heater water control
valve is closed (heat off). This is done to prevent
coolant flow with scale and other deposits from
entering the heater core.
Connect the water suppl y hose and ai r suppl y hose
to the fl ushi ng gun. Al l ow the engi ne to fi l l wi th
water. When the engi ne i s fi l l ed, appl y ai r i n short
bl asts, al l owi ng the system to fi l l between ai r bl asts.
Conti nue unti l cl ean water fl ows through the l ead
away hose. For more i nformati on, refer to operati ng
i nstructi ons suppl i ed wi th fl ushi ng equi pment.
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng and i nstal l thermostat. I nstal l the ther-
mostat housi ng wi th a new repl acement rubber seal .
Refer to Thermostat I nstal l ati on. Connect the radi a-
tor hoses. Refi l l the cool i ng system wi th the correct
anti freeze/water mi xture.
CHEMICAL CLEANING
I n some i nstances, use a radi ator cl eaner (Mopar
Radi ator Kl een or equi val ent) before fl ushi ng. Thi s
wi l l soften scal e and other deposi ts and ai d the fl ush-
i ng operati on.
CAUTION: Be sure instructions on the container
are followed.
ADJ USTMENTS
DRIVE BELT TENSION
I ni ti al bel t adjustment i s done wi th a adjustabl e
tensi oner pul l ey. After the i ni ti al adjustment i s per-
formed, an automati c bel t tensi oner i s used to mai n-
tai n correct bel t tensi on at al l ti mes. For other
tensi oner i nformati on and removal /i nstal l ati on proce-
dures, refer to Automati c Bel t Tensi oner i n thi s
group. Due to use of thi s bel t tensi oner, DO NOT
attempt to use a bel t tensi on gauge on the 2.5L di e-
sel engi ne.
SPECIFICATIONS
COOLING SYSTEM CAPACITY
2.5L Diesel Engine: 9.8 Liters (10.4 qts.)
THERMOSTAT
Starts to open at 80C (176F).
DESCRIPTION TORQUE
Automatic Belt Tensioner-to-Mounting Bracket
Bol t (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
Automatic Belt Tensioner-to-Block
Bol ts (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Nm
Coolant Tank
Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Fan Shroud-to-Radiator Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nm
Fan Blade-to-Thermal Viscous Fan Drive
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm
Hose
Cl amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nm
Radiator-to-A/C Condenser Isolator
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
Thermal Viscous Fan Drive-to-Fan Hub
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Nm
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm
Water Pump Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm
Water Pump Pulley
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm
BATTERY
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BATTERY MOUNTING . . . . . . . . . . . . . . . . . . . . 3
BATTERY SIZE AND RATINGS . . . . . . . . . . . . . . 2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUILT-IN TEST INDICATOR . . . . . . . . . . . . . . . . 6
HYDROMETER TEST . . . . . . . . . . . . . . . . . . . . . 6
IGNITION-OFF DRAW TEST . . . . . . . . . . . . . . . 10
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 8
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . 11
SERVICE PROCEDURES
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . 12
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
GENERAL INFORMATION
OVERVIEW
The battery, starti ng, and chargi ng systems oper-
ate wi th one another, and must be tested as a com-
pl ete system. I n order for the vehi cl e to start and
charge properl y, al l of the components i nvol ved i n
these systems must perform wi thi n speci fi cati ons.
Group 8A covers the battery, Group 8B covers the
starti ng system, and Group 8C covers the chargi ng
system. Refer to Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams. We have
separated these systems to make i t easi er to l ocate
the i nformati on you are seeki ng wi thi n thi s Servi ce
Manual . However, when attempti ng to di agnose any
of these systems, i t i s i mportant that you keep thei r
i nterdependency i n mi nd.
The di agnosti c procedures used i n these groups
i ncl ude the most basi c conventi onal di agnosti c meth-
ods, to the more sophi sti cated On-Board Di agnosti cs
(OBD) bui l t i nto the Powertrai n Control Modul e
(PCM). Use of a i nducti on mi l l i ampere ammeter, vol t/
ohmmeter, battery charger, carbon pi l e rheostat (l oad
tester), and 12-vol t test l amp may be requi red.
Al l OBD-sensed systems are moni tored by the
PCM. Each moni tored ci rcui t i s assi gned a Di agnos-
ti c Troubl e Code (DTC). The PCM wi l l store a DTC i n
el ectroni c memory for any fai l ure i t detects. See the
On-Board Di agnosti cs Test i n Group 8C - Chargi ng
System for more i nformati on.
INTRODUCTION
Thi s secti on covers onl y battery di agnosti c and ser-
vi ce procedures. For battery mai ntenance procedures,
refer to Group 0 - Lubri cati on and Mai ntenance.
Whi l e battery chargi ng can be consi dered a mai nte-
nance procedure, battery chargi ng i nformati on i s
l ocated i n thi s group. Thi s was done because the bat-
tery must be ful l y-charged before any di agnosi s can
be performed.
The factory-i nstal l ed l ow-mai ntenance battery has
removabl e battery cel l caps. Water can be added to
thi s battery. The battery i s not seal ed and has vent
hol es i n the cel l caps (Fi g. 1). The chemi cal composi -
ti on wi thi n the l ow-mai ntenance battery reduces bat-
tery gassi ng and water l oss, at normal charge and
di scharge rates.
Rapi d l oss of el ectrol yte can be caused by an over-
chargi ng condi ti on. Be certai n to di agnose the charg-
i ng system before returni ng the vehi cl e to servi ce.
Refer to Group 8C - Chargi ng System for more i nfor-
mati on.
The factory-i nstal l ed battery i n a North Ameri can-
bui l t vehi cl e al so has a bui l t-i n test i ndi cator
(hydrometer). The col or vi si bl e i n the si ght gl ass of
Fig. 1 Low-Maintenance Battery - Typical
ELECTROLYTE LEVEL POSITIVE POST VENT TEST INDICA- TOR VENT NEGATIVE POST GREEN BALL PLATE GROUPS LOW-MAINTE- NANCE BAT- TERY
ZG BATTERY 8A - 1
the i ndi cator wi l l reveal the battery condi ti on. See
Bui l t-I n Test I ndi cator i n thi s group for more i nfor-
mati on. The factory-i nstal l ed batteri es i n vehi cl es
bui l t outsi de of North Ameri ca do not have a bui l t-i n
test i ndi cator.
I t i s i mportant that the battery, starti ng, and
chargi ng systems be thoroughl y tested and i nspected
any ti me a battery needs to be charged or repl aced.
The cause of abnormal di scharge, overchargi ng, or
earl y battery fai l ure must be di agnosed and corrected
before a battery i s repl aced or returned to servi ce.
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.
BATTERY
The storage battery i s a devi ce used to store el ec-
tri cal energy potenti al i n a chemi cal form. When an
el ectri cal l oad i s appl i ed to the battery termi nal s, an
el ectrochemi cal reacti on occurs wi thi n the battery.
Thi s reacti on causes the battery to di scharge el ectri -
cal current.
The battery i s made up of si x i ndi vi dual cel l s that
are connected i n seri es. Each cel l contai ns posi ti vel y
charged pl ate groups made of l ead oxi de, and nega-
ti vel y charged pl ate groups made of sponge l ead.
These di ssi mi l ar metal pl ates are submerged i n a
sul furi c aci d and water sol uti on cal l ed an el ectrol yte.
As the battery di scharges, a gradual chemi cal
change takes pl ace wi thi n each cel l . The sul furi c aci d
i n the el ectrol yte combi nes wi th the pl ate materi al s,
causi ng both pl ates to sl owl y change to l ead sul fate.
At the same ti me, oxygen from the posi ti ve pl ate
materi al combi nes wi th hydrogen from the sul furi c
aci d, causi ng the el ectrol yte to become mai nl y water.
The chemi cal changes wi thi n the battery are
caused by the movement of excess or free el ectrons
between the posi ti ve and negati ve pl ate groups. Thi s
movement of el ectrons produces a fl ow of el ectri cal
current through the l oad devi ce attached to the bat-
tery termi nal s.
As the pl ate materi al s become more si mi l ar chem-
i cal l y, and the el ectrol yte becomes l ess aci d, the vol t-
age potenti al of each cel l i s reduced. However, by
chargi ng the battery wi th a vol tage hi gher than that
of the battery, the battery di schargi ng process i s
reversed.
Chargi ng the battery gradual l y changes the sul -
fated l ead pl ates back i nto sponge l ead and l ead
oxi de, and the water back i nto sul furi c aci d. Thi s
acti on restores the di fference i n the el ectron charges
deposi ted on the pl ates, and the vol tage potenti al of
the battery cel l s.
For a battery to remai n useful , i t must be abl e to
produce hi gh-amperage current over an extended
peri od. A battery must al so be abl e to accept a
charge, so that i ts vol tage potenti al may be restored.
I n addi ti on to produci ng and stori ng el ectri cal
energy, the battery serves as a capaci tor, or vol tage
stabi l i zer, for a vehi cl es el ectri cal system. I t absorbs
most abnormal or transi ent vol tages caused by the
swi tchi ng of any of the vehi cl es el ectri cal compo-
nents.
The battery i s vented to rel ease excess hydrogen
gas that i s created when the battery i s bei ng charged
or di scharged. However, even wi th these vents, the
hydrogen gas can col l ect i n or around the battery. I f
hydrogen gas i s exposed to fl ame or sparks, i t may
i gni te.
I f the el ectrol yte l evel i s l ow, the battery may arc
i nternal l y and expl ode. I f the battery i s equi pped
wi th removabl e cel l caps, add di sti l l ed water when-
ever the el ectrol yte l evel i s bel ow the top of the
pl ates. I f the battery cel l caps cannot be removed, the
battery must be repl aced i f the el ectrol yte l evel
becomes l ow.
BATTERY SIZE AND RATINGS
The battery Group Si ze number, the Col d Cranki ng
Amperage (CCA) rati ng, and the Reserve Capaci ty
(RC) rati ng or Ampere-Hours (AH) rati ng can be
found on the ori gi nal equi pment battery l abel . Be
certai n that a repl acement battery has the correct
Group Si ze number, as wel l as CCA, and RC or AH
rati ngs that equal or exceed the ori gi nal equi pment
speci fi cati on for the vehi cl e bei ng servi ced.
See the Battery Cl assi fi cati ons and Rati ngs chart
i n Speci fi cati ons at the back of thi s group for more
i nformati on. Battery si zes and rati ngs are di scussed
i n more detai l bel ow.
GROUP SIZE
The outsi de di mensi ons and termi nal pl acement of
the battery conform to standards establ i shed by the
Battery Counci l I nternati onal (BCI ). Each battery i s
assi gned a BCI Group Si ze number to hel p i denti fy a
correctl y-si zed repl acement.
COLD CRANKING AMPERAGE
The Col d Cranki ng Amperage (CCA) rati ng speci -
fi es how much current (i n amperes) the battery can
8A - 2 BATTERY ZG
del i ver for thi rty seconds at -18 C (0 F). Termi nal
vol tage must not fal l bel ow 7.2 vol ts duri ng or after
the thi rty second di scharge peri od. The CCA requi red
i s general l y hi gher as engi ne di spl acement i ncreases,
dependi ng al so upon the starter current draw
requi rements.
RESERVE CAPACITY
The Reserve Capaci ty (RC) rati ng speci fi es the
ti me (i n mi nutes) i t takes for battery termi nal vol t-
age to fal l bel ow 10.5 vol ts, at a di scharge rate of 25
amperes. RC i s determi ned wi th the battery ful l y-
charged at 26.7 C (80 F). Thi s rati ng esti mates how
l ong the battery mi ght l ast after a chargi ng system
fai l ure, under mi ni mum el ectri cal l oad.
AMPERE-HOURS
The Ampere-Hours (AH) rati ng speci fi es the cur-
rent (i n amperes) that a battery can del i ver steadi l y
for twenty hours, wi th the vol tage i n the battery not
fal l i ng bel ow 10.5 vol ts. Thi s rati ng i s al so someti mes
referred to as the twenty-hour di scharge rati ng.
BATTERY MOUNTING
The battery i s mounted to a mol ded pl asti c tray
l ocated i n the ri ght front corner of the engi ne com-
partment. A U-nut i s hel d i n a formati on on each si de
of the battery tray. A hol ddown strap fi ts across the
top of the battery case and thermoguard. To secure
the battery i n the tray, a bol t passes through the
hol ddown strap on each si de of the battery, and i s
threaded i nto the U-nut on each si de of the battery
tray.
The battery tray i s secured wi th three screws to
the front wheel house extensi on panel , forward of the
ri ght front wheel . The tray i s al so secured to the
ri ght fender i nner shi el d wi th two screws.
A vacuum reservoi r for the vehi cl e speed control
and heater-A/C systems i s mounted to the undersi de
of the battery tray. Refer to Group 8H - Vehi cl e
Speed Control System or Group 24 - Heati ng and Ai r
Condi ti oni ng for more i nformati on on the vacuum
reservoi r.
On some model s, a hol e i n the bottom of the bat-
tery tray i s fi tted wi th a battery temperature sensor.
Model s wi thout the battery temperature sensor have
a pl ug fi tted to thi s hol e. Refer to Group 8C - Charg-
i ng System for more i nformati on on the battery tem-
perature sensor.
When i nstal l i ng a battery, be certai n that the hol d-
down fasteners are ti ghtened to the proper speci fi ca-
ti ons. I mproper hol ddown fastener ti ghtness, whether
too l oose or too ti ght, can resul t i n damage to the
battery. See the Battery Removal and I nstal l ati on
procedures for the correct hol ddown fastener ti ght-
ness speci fi cati ons.
BATTERY
The battery must be compl etel y charged and the
top, posts, and termi nal cl amps shoul d be properl y
cl eaned before di agnosti c procedures are performed.
See the Battery Chargi ng procedure i n thi s group for
more i nformati on.
WARNING:
IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
The condi ti on of a battery i s determi ned by two cri -
teri a:
1. State-Of-Charge - Thi s can be determi ned by
vi ewi ng the bui l t-i n test i ndi cator, by checki ng the
speci fi c gravi ty of the el ectrol yte (hydrometer test),
or by checki ng the battery vol tage (open-ci rcui t vol t-
age test).
2. Cranking Capacity - Thi s can be determi ned
by performi ng a battery l oad test, whi ch measures
the abi l i ty of the battery to suppl y hi gh-amperage
current.
Fi rst, determi ne the battery state-of-charge. Thi s
can be done i n one of three ways. I f the battery has a
bui l t-i n test i ndi cator, vi ew the test i ndi cator to
determi ne the state-of-charge. I f the battery has no
test i ndi cator, but has removabl e cel l caps, perform
the hydrometer test to determi ne the state-of-charge.
I f the cel l caps are not removabl e, or a hydrometer i s
not avai l abl e, perform the open-ci rcui t vol tage test to
determi ne the state-of-charge.
The battery must be charged before proceedi ng
wi th a l oad test i f:
ZG BATTERY 8A - 3
The bui l t-i n test i ndi cator has a bl ack or dark
col or vi si bl e.
The temperature corrected speci fi c gravi ty i s
l ess than 1.235.
The open-ci rcui t vol tage i s l ess than 12.4 vol ts.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
requi red. A ful l y-charged battery must be l oad tested
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. See Charging A
Completely Discharged Battery in this group for
more information.
A battery i s ful l y-charged when:
Al l cel l s are gassi ng freel y duri ng chargi ng.
A green col or i s vi si bl e i n the si ght gl ass of the
bui l t-i n test i ndi cator.
Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty.
Open-ci rcui t vol tage i s 12.4 vol ts or greater.
Battery Diagnosis
Condition Possible Causes Correction
The battery seems weak or dead
when attempting to start the
engine.
1. The battery has an incorrect size
or rating for this vehicle.
2. The battery is physically
damaged.
3. The battery terminal connections
are loose or corroded.
4. The battery is discharged.
5. The electrical system is faulty.
6. The battery is faulty.
7. The starting system is faulty.
8. The charging system is faulty.
1. See Specifications in this group.
Replace the incorrect battery with
the correct battery, if required.
2. Inspect the battery for loose
terminal posts or a cracked and
leaking case. Replace the battery, if
damaged.
3. See the Voltage Drop Test in this
group. Clean and tighten the battery
terminal connections, if required.
4. See the Test Indicator, the
Hydrometer Test, or the Open-Circuit
Voltage Test in this group to
determine the battery state-of-
charge. Charge the battery, if
required.
5. See the Ignition-Off Draw Test in
this group. Repair the electrical
system, if required.
6. See the Load Test in this group to
determine the battery condition.
Replace the battery, if required.
7. Refer to Group 8B - Starting
Systems for more information.
Repair the starting system, if
required.
8. Refer to Group 8C - Charging
Repair the charging system, if
required.
8A - 4 BATTERY ZG
Battery Diagnosis
Condition Possible Causes Correction
The battery state-of-charge cannot
be maintained.
1. The battery has an incorrect size
or rating for this vehicle.
2. The battery terminal connections
are loose or corroded.
3. The generator drive belt is loose
or worn.
4. The electrical system is faulty.
5. The battery is faulty.
6. The starting system is faulty.
7. The charging system is faulty.
8. Electrical loads exceed the output
of the charging system.
9. Slow driving or prolonged idling
with high-amperage draw systems in
use.
1. See Specifications in this group.
Replace the incorrect battery with
the correct battery, if required.
2. See the Voltage Drop Test in this
group. Clean and tighten the battery
terminal connections, if required.
3. Refer to Group 7 - Cooling
Replace or adjust the generator
drive belt, if required.
4. See the Ignition-Off Draw Test in
this group. Repair the electrical
system, if required.
5. See the Load Test in this group to
determine the battery condition.
Replace the battery, if required.
6. Refer to Group 8B - Starting
Repair the starting system, if
required.
7. Refer to Group 8C - Charging
Repair the charging system, if
required.
8. Inspect the vehicle for aftermarket
electrical equipment which might
cause excessive electrical loads.
9. Advise the vehicle operator, as
required.
The battery will not accept a
charge.
1. The battery is faulty. 1. See Battery Charging in this
group. Replace the faulty battery, if
required.
ZG BATTERY 8A - 5
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
1. Corroded or l oose battery posts and termi nal
cl amps.
2. A l oose or worn generator dri ve bel t.
3. El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
4. Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
5. A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw. See the I gni ti on-Off Draw Test pro-
cedure i n thi s group for more i nformati on.
6. A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Group 8C - Chargi ng System for more
i nformati on.
7. A faul ty or i ncorrect battery.
BUILT-IN TEST INDICATOR
A test i ndi cator (hydrometer) bui l t i nto the top of
the battery case provi des vi sual i nformati on for bat-
tery testi ng (Fi g. 2). Li ke a hydrometer, the bui l t-i n
test i ndi cator measures the speci fi c gravi ty of the
el ectrol yte. The test i ndi cator reveal s the battery
state-of-charge; however, i t wi l l not reveal the crank-
i ng capaci ty of the battery. A l oad test must be per-
formed to determi ne the battery cranki ng capaci ty.
See the Load Test procedure i n thi s group for more
i nformati on.
WARNING:
MAY RESULT.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n test i ndi -
cator, i t i s i mportant that the battery be l evel and
have a cl ean si ght gl ass. Addi ti onal l i ght may be
requi red to vi ew the i ndi cator. Do not use open
flame as a source of additional light.
To read the bui l t-i n test i ndi cator, l ook i nto the
si ght gl ass and note the col or of the i ndi cator (Fi g. 3).
Refer to the fol l owi ng descri pti on, as the col or i ndi -
cates:
Green - i ndi cates 75% to 100% state-of-charge.
The battery i s adequatel y charged for further testi ng
or return to use. I f the vehi cl e wi l l not crank for a
mi ni mum of fi fteen seconds wi th a ful l y-charged bat-
tery, perform the Load Test procedure as descri bed i n
thi s group.
Black or Dark - i ndi cates 0% to 75% state-of-
charge. The battery i s i nadequatel y charged and
must be charged unti l a green i ndi cati on i s vi si bl e i n
the si ght gl ass (12.4 vol ts or more), before the bat-
tery i s tested further or returned to servi ce. See the
Battery Chargi ng procedure i n thi s group for more
i nformati on. Al so see Abnormal Battery Di schargi ng
i n thi s group for possi bl e causes of the di scharged
condi ti on.
Clear or Bright - i ndi cates a l ow el ectrol yte
l evel . The el ectrol yte l evel i n the battery i s bel ow the
test i ndi cator. A mai ntenance-free battery wi th non-
removabl e cel l caps must be repl aced i f the el ectro-
l yte l evel i s l ow. Water must be added to a l ow-
mai ntenance battery wi th removabl e cel l caps before
i t i s charged. See the Battery Chargi ng procedure i n
thi s group for more i nformati on. A l ow el ectrol yte
l evel may be caused by an overchargi ng condi ti on.
Refer to Group 8C - Chargi ng System to di agnose an
overchargi ng condi ti on.
HYDROMETER TEST
The hydrometer test reveal s the battery state-of-
charge by measuri ng the speci fi c gravi ty of the el ec-
Fig. 2 Built-In Test Indicator
SIGHT GLASS PLASTICROD BATTERYTOP GREEN BALL
8A - 6 BATTERY ZG
trol yte. Thi s test cannot be performed on
mai ntenance-free batteri es wi th non-removabl e cel l
caps. I f the battery has non-removabl e cel l caps, see
the Bui l t-I n Test I ndi cator or the Open-Ci rcui t Vol t-
age Test procedures i n thi s group.
Speci fi c gravi ty i s a compari son of the densi ty of
the el ectrol yte to the densi ty of pure water. Pure
water has a speci fi c gravi ty of 1.000, and sul furi c
aci d has a speci fi c gravi ty of 1.835. Sul furi c aci d
makes up approxi matel y 35% of the el ectrol yte by
wei ght, or 24% by vol ume.
I n a ful l y-charged battery the el ectrol yte wi l l have
a temperature-corrected speci fi c gravi ty of 1.260 to
1.290. However, a speci fi c gravi ty of 1.235 or above i s
sati sfactory for battery l oad testi ng and/or return to
servi ce.
WARNING:
MAY RESULT.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. Then
remove the cel l caps and check the el ectrol yte l evel .
Add di sti l l ed water i f the el ectrol yte l evel i s bel ow
the top of the battery pl ates.
Refer to the i nstructi ons suppl i ed wi th the hydrom-
eter for recommendati ons on the correct use of the
hydrometer. Remove onl y enough el ectrol yte from the
battery cel l so that the fl oat i s off the bottom of the
hydrometer barrel wi th pressure on the bul b
rel eased.
CAUTION: Exercise care when inserting the tip of
the hydrometer into a cell to avoid damaging the
plate separators. Damaged plate separators can
cause early battery failure.
To read the hydrometer correctl y, hol d i t wi th the
top surface of the el ectrol yte at eye l evel (Fi g. 4).
Hydrometer fl oats are general l y cal i brated to i ndi -
cate the speci fi c gravi ty correctl y onl y at 26.7 C (80
F). When testi ng the speci fi c gravi ty at any other
temperature, a correcti on factor i s requi red.
The correcti on factor i s approxi matel y a speci fi c
gravi ty val ue of 0.004, referred to as four poi nts of
speci fi c gravi ty. For each 5.5 C above 26.7 C (10 F
above 80 F), add four poi nts. For each 5.5 C bel ow
26.7 C (10 F bel ow 80 F), subtract four poi nts.
Al ways correct the speci fi c gravi ty for temperature
vari ati on. Test the speci fi c gravi ty of the el ectrol yte
i n each battery cel l .
Fig. 3 Built-In Test Indicator Sight Glass
TEST INDICATOR/STATE-OF- CHARGE
LOW ELECTROLYTE
Fig. 4 Hydrometer - Typical
BULB SURFACE COHESION SPECIFIC GRAVITY READING TEMPERATURE READING HYDROMETER BARREL FLOAT
ZG BATTERY 8A - 7
EXAMPLE: A battery i s tested at -12.2 C (10 F)
and has a speci fi c gravi ty of 1.240. Determi ne the
actual speci fi c gravi ty as fol l ows:
(1) Determi ne the number of degrees above or
bel ow 26.7 C (80 F):
26.6 C - -12.2 C = 38.8 C (80 F -
10 F = 70 F)
(2) Di vi de the resul t from Step 1 by 5.5 (10):
38.8 C 5.5 = 7 (70 F 10 = 7)
(3) Mul ti pl y the resul t from Step 2 by the temper-
ature correcti on factor (0.004):
7 X 0.004 = 0.028
(4) The temperature at testi ng was bel ow 26.7 C
(80 F); therefore, the temperature correcti on factor
i s subtracted:
1.240 - 0.028 = 1.212
The corrected speci fi c gravi ty of the battery i n thi s
exampl e i s 1.212.
I f the speci fi c gravi ty of al l cel l s i s above 1.235, but
the vari ati on between cel l s i s more than fi fty poi nts
(0.050), the battery shoul d be repl aced. I f the speci fi c
gravi ty of one or more cel l s i s l ess than 1.235, charge
the battery at a rate of approxi matel y fi ve amperes.
Conti nue chargi ng the battery unti l three consecu-
ti ve speci fi c gravi ty tests, taken at one-hour i nter-
val s, are constant. I f the cel l speci fi c gravi ty
vari ati on i s more than fi fty poi nts (0.050) at the end
of the charge peri od, repl ace the battery.
When the speci fi c gravi ty of al l cel l s i s above 1.235,
and the cel l vari ati on i s l ess than fi fty poi nts (0.050),
the battery may be l oad tested to determi ne i ts
cranki ng capaci ty. See the Load Test procedure i n
thi s group for more i nformati on.
OPEN-CIRCUIT VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the state-of-charge of a battery. Thi s test can be
used i n pl ace of the hydrometer test when a hydrom-
eter i s not avai l abl e, or for mai ntenance-free batter-
i es wi th non-removabl e cel l caps.
WARNING:
MAY RESULT.
Before proceedi ng wi th thi s test, compl etel y charge
the battery as descri bed i n the Battery Chargi ng pro-
cedure i n thi s group.
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the head l amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (refer to the i nstructi ons provi ded wi th the
vol tmeter), measure the open-ci rcui t vol tage (Fi g. 5).
See the Open-Ci rcui t Vol tage chart. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty. See the Load Test procedure i n thi s group
for more i nformati on.
Fig. 5 Testing Open-Circuit Voltage - Typical
Open Circuit Voltage
Open Circuit Volts Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
8A - 8 BATTERY ZG
LOAD TEST
A battery l oad test wi l l veri fy the battery cranki ng
capaci ty. The test i s based on the Col d Cranki ng
Amperage (CCA) rati ng of the battery. Refer to the
battery l abel , or see the Battery Cl assi fi cati ons and
Rati ngs chart i n Speci fi cati ons at the back of thi s
group for the CCA rati ng of the factory-i nstal l ed bat-
tery.
WARNING:
MAY RESULT.
Before proceedi ng wi th thi s test, compl etel y charge
the battery as descri bed i n the Battery Chargi ng pro-
cedure i n thi s group.
(1) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst. The battery top and posts shoul d be
cl ean.
(2) Connect a sui tabl e vol t-ammeter-l oad tester
(Fi g. 6) to the battery posts (Fi g. 7). Refer to the
operati ng i nstructi ons provi ded wi th the tester bei ng
used. Check the open-ci rcui t vol tage (no l oad) of the
battery. Open-ci rcui t vol tage must be 12.4 vol ts or
greater.
(3) Rotate the l oad control knob (carbon pi l e rheo-
stat) to appl y a 300 ampere l oad to the battery for
fi fteen seconds, then return the control knob to the
Off posi ti on (Fi g. 8). Thi s wi l l remove the surface
charge from the battery.
(4) Al l ow the battery to stabi l i ze to open-ci rcui t
vol tage. I t may take up to fi ve mi nutes for the bat-
tery vol tage to stabi l i ze.
(5) Rotate the l oad control knob to mai ntai n a l oad
equal to 50% of the CCA rati ng of the battery (Fi g.
9). After fi fteen seconds, record the l oaded vol tage
readi ng, then return the l oad control knob to the Off
posi ti on.
(6) The vol tage drop wi l l vary wi th the battery
temperature at the ti me of the l oad test. The battery
temperature can be esti mated by usi ng the ambi ent
temperature duri ng the past several hours. I f the
battery has been charged, boosted, or l oaded a few
Fig. 6 Volt-Ammeter-Load Tester - Typical
Fig. 7 Volt-Ammeter-Load Tester Connections-
Typical
INDUCTION AMMETER CLAMP NEGATIVE CLAMP POSITIVE CLAMP
Fig. 8 Remove Surface Charge from Battery- Typical
ZG BATTERY 8A - 9
mi nutes pri or to the test, the battery wi l l be some-
what warmer. See the Load Test Temperature chart
for the proper l oaded vol tage readi ng.
(7) I f the vol tmeter readi ng fal l s bel ow 9.6 vol ts, at
a mi ni mum battery temperature of 21 C (70 F), the
battery i s faul ty and must be repl aced.
IGNITION-OFF DRAW TEST
I gni ti on-Off Draw (I OD) refers to power bei ng
drai ned from the battery wi th the i gni ti on swi tch i n
the Off posi ti on. A normal vehi cl e el ectri cal system
wi l l draw from fi ve to thi rty mi l l i amperes (0.005 to
0.030 ampere) wi th the i gni ti on swi tch i n the Off
posi ti on, and al l non-i gni ti on control l ed ci rcui ts i n
proper worki ng order. The thi rty mi l l i amperes are
needed to enabl e the memory functi ons for the Pow-
ertrai n Control Modul e (PCM), di gi tal cl ock, el ectron-
i cal l y tuned radi o, and other modul es whi ch may
vary wi th the vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the Power Di stri buti on Center (PDC). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
El ectri cal i tems l eft on
Faul ty or i mproperl y adjusted swi tches
Faul ty or shorted el ectroni c modul es and compo-
nents
An i nternal l y shorted generator
I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over thi rty mi l l i amperes, the probl em
must be found and corrected before repl aci ng a bat-
tery. I n most cases, the battery can be charged and
returned to servi ce after the excessi ve I OD has been
corrected.
DIAGNOSIS
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th a i l l umi -
nated entry system or el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes.
(2) Determi ne that the underhood l amp i s operat-
i ng properl y, then unpl ug the l amp wi re harness con-
nector or remove the l amp bul b.
(3) Di sconnect the battery negati ve cabl e.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e
cl amp and the battery negati ve termi nal post. Make
sure that the doors remai n cl osed so that the i l l umi -
nated entry system i s not acti vated. The mul ti -meter
amperage readi ng may remai n hi gh for up to three
mi nutes, or may not gi ve any readi ng at al l whi l e set
i n the hi ghest amperage scal e, dependi ng upon the
el ectri cal equi pment on the vehi cl e. The mul ti -meter
l eads must be securel y cl amped to the battery nega-
ti ve cabl e cl amp and the battery negati ve termi nal
post. I f conti nui ty between the battery negati ve ter-
mi nal post and the negati ve cabl e cl amp i s l ost dur-
i ng any part of the I OD test, the el ectroni c ti mer
functi on wi l l be acti vated and al l of the tests wi l l
have to be repeated.
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or non-exi stent, dependi ng upon the el ectri cal
equi pment on the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove each fuse or ci rcui t breaker
(refer to Group 8W - Wi ri ng Di agrams for more i nfor-
mati on) unti l the amperage readi ng becomes very
l ow, or non-exi stent. Thi s wi l l i sol ate each ci rcui t and
i denti fy the source of the hi gh-amperage I OD. I f the
amperage readi ng remai ns hi gh after di sconnecti ng
each fuse and ci rcui t breaker, unpl ug the wi re har-
ness connector from the generator. I f the amperage
Fig. 9 Load 50% CCA Rating - Note Voltage- Typical
Load Test Temperature
Minimum Voltage
Temperature
F C
9.6 volts 70and above 21and above
9.5 volts 60 16
9.4 volts 50 10
9.3 volts 40 4
9.1 volts 30 -1
8.9 volts 20 -7
8.7 volts 10 -12
8.5 volts 0 -18
8A - 10 BATTERY ZG
readi ng now becomes very l ow or non-exi stent, refer
to Group 8C - Chargi ng System to di agnose the
faul ty chargi ng system. After the hi gh-amperage I OD
has been corrected, swi tch the mul ti -meter to pro-
gressi vel y l ower amperage scal es and, i f necessary,
repeat the fuse and ci rcui t breaker removal process
to i denti fy and correct the sources of excessi ve I OD.
I t i s now safe to sel ect the l owest mi l l i ampere scal e
of the mul ti -meter to check the l ow-amperage I OD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed thi rty mi l l i amperes
(0.030 ampere). I f the draw exceeds thi rty mi l l i am-
peres, i sol ate each ci rcui t by removi ng the ci rcui t
breakers and fuses. The mul ti -meter readi ng wi l l
drop to wi thi n the acceptabl e l i mi t when the source
of the excessi ve draw i s di sconnected. Repai r thi s ci r-
cui t as requi red; whether a wi ri ng short, i ncorrect
swi tch adjustment, or a component fai l ure i s at faul t.
VOLTAGE DROP TEST
The vol tage drop test wi l l determi ne i f there i s
excessi ve resi stance i n the battery termi nal connec-
ti ons or the battery cabl es. When performi ng these
tests, i t i s i mportant to remember that the vol tage
drop i s gi vi ng an i ndi cati on of the resi stance between
the two poi nts at whi ch the vol tmeter probes are
attached.
Example: When testi ng the resi stance of the bat-
tery posi ti ve cabl e, touch the vol tmeter l eads to the
battery posi ti ve cabl e cl amp and the cabl e connector
at the starter sol enoi d. I f you probe the battery pos-
i ti ve termi nal post and the cabl e connector at the
starter sol enoi d, you are readi ng the combi ned vol t-
age drop i n the battery posi ti ve cabl e cl amp-to-termi -
nal post connecti on and the battery posi ti ve cabl e.
WARNING:
MAY RESULT.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng the
tests, be certai n the fol l owi ng procedures are accom-
pl i shed:
Battery i s ful l y-charged as descri bed i n thi s
group.
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and ful l y depress the cl utch
pedal .
Unpl ug the Automati c ShutDown (ASD) rel ay to
prevent a gasol i ne engi ne from starti ng. The ASD
rel ay i s l ocated i n the Power Di stri buti on Center
(PDC). Refer to the PDC l abel for ASD rel ay i denti -
fi cati on and l ocati on. To prevent a di esel engi ne from
starti ng, unpl ug the fuel shut off sol enoi d wi re har-
ness connector (Fi g. 10).
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
Fig. 10 Fuel Shut Off Solenoid Connector- Diesel
Engine
GENERATOR FUEL INJECTOR PUMP FUEL SHUT-OFF SOLENOID FWD FUEL SHUT-OFF SOLENOID CONNECTOR
ZG BATTERY 8A - 11
cabl e cl amp (Fi g. 11). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor contact between
the cabl e cl amp and the termi nal post.
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
cl amp (Fi g. 12). Rotate and hol d the i gni ti on swi tch
i n the Start posi ti on. Observe the vol tmeter. I f vol t-
age i s detected, correct the poor contact between the
cabl e cl amp and the termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve termi nal post and the starter sol e-
noi d battery termi nal stud (Fi g. 13). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery cabl e connecti on at the sol enoi d.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
battery negati ve termi nal post and a good cl ean
ground on the engi ne bl ock (Fi g. 14). Rotate and hol d
ti ghten the battery negati ve cabl e attachment on the
engi ne bl ock. Repeat the test. I f the readi ng i s sti l l
above 0.2 vol t, repl ace the faul ty battery negati ve
cabl e.
SERVICE PROCEDURES
BATTERY CHARGING
A battery i s ful l y-charged when:
Al l cel l s are gassi ng freel y duri ng battery charg-
i ng.
A green col or i s vi si bl e i n the si ght gl ass of the
bui l t-i n test i ndi cator.
Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty.
Open-ci rcui t vol tage i s 12.4 vol ts or above.
Fig. 11 Test Battery Negative ConnectionResistance
- Typical
VOLTMETER BATTERY
Fig. 12 Test Battery Positive ConnectionResistance
- Typical
VOLTMETER BATTERY
Fig. 13 Test Battery Positive Cable Resistance-
Typical
BATTERY VOLTMETER STARTER MOTOR
Fig. 14 Test Ground Circuit Resistance -Typical
VOLTMETER ENGINE GROUND BATTERY
8A - 12 BATTERY ZG
WARNING:
MAY RESULT.
CAUTION:
Always disconnect and isolate the battery neg-
ative cable before charging a battery. Do not exceed
sixteen volts while charging a battery. Damage to
the vehicle electrical system components may
result.
Battery electrolyte will bubble inside the bat-
tery case during normal battery charging. Electro-
lyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
The battery should not be hot to the touch. If
the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing
the charging operation. Damage to the battery may
result.
Some battery chargers are equi pped wi th pol ari ty-
sensi ng ci rcui try. Thi s ci rcui try protects the charger
and/or the battery from bei ng damaged i f they are
i mproperl y connected. I f the battery state-of-charge
i s too l ow for the pol ari ty-sensi ng ci rcui try to detect,
the charger wi l l not operate. Thi s makes i t appear
that the battery wi l l not accept chargi ng current.
Refer to the i nstructi ons provi ded wi th the battery
charger to bypass the pol ari ty-sensi ng ci rcui try.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty. I f the battery wi l l endure a l oad
test, return the battery to use. I f the battery wi l l not
endure a l oad test, i t i s faul ty and must be repl aced.
Cl ean and i nspect the battery hol ddowns, tray, ter-
mi nal s, posts, and top before compl eti ng servi ce. See
the Battery Removal and I nstal l ati on procedures i n
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 15). I f the
readi ng i s bel ow ten vol ts, the charge current wi l l be
l ow. I t coul d take some ti me before the battery
accepts a current greater than a few mi l l i amperes.
Such l ow current may not be detectabl e on the
ammeters bui l t i nto many chargers.
(2) Di sconnect and i sol ate the battery negati ve
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the charger and/or the
battery from bei ng damaged i f they are i mproperl y
connected. I f the battery state-of-charge i s too l ow for
the pol ari ty-sensi ng ci rcui try to detect, the charger
wi l l not operate. Thi s makes i t appear that the bat-
tery wi l l not accept chargi ng current. Refer to the
i nstructi ons provi ded wi th the battery charger to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e charger
current at vari ous vol tages i s shown i n the Charge
Rate chart. I f the charge current i s sti l l not measur-
abl e at the end of the chargi ng ti me, the battery i s
faul ty and must be repl aced. I f the charge current i s
measurabl e duri ng the chargi ng ti me, the battery
Fig. 15 Voltmeter Accurate to 1/10 Volt Connected-
Typical
ZG BATTERY 8A - 13
may be good and the chargi ng shoul d be compl eted i n
the normal manner.
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
Battery Capacity - A compl etel y di scharged
heavy-duty battery requi res twi ce the chargi ng ti me
of a smal l capaci ty battery.
Temperature - A l onger ti me wi l l be needed to
charge a battery at -18 C (0 F) than at 27 C (80
F). When a fast charger i s connected to a col d bat-
tery, the current accepted by the battery wi l l be very
l ow at fi rst. As the battery warms, i t wi l l accept a
hi gher chargi ng current rate (amperage).
Charger Capacity - A charger that suppl i es
onl y fi ve amperes wi l l requi re a l onger chargi ng
ti me. A charger that suppl i es twenty amperes or
more wi l l requi re a shorter chargi ng ti me.
State-Of-Charge - A compl etel y di scharged
battery requi res more chargi ng ti me than a parti al l y
di scharged battery. El ectrol yte i s nearl y pure water
i n a compl etel y di scharged battery. At fi rst, the
chargi ng current (amperage) wi l l be l ow. As the bat-
tery charges, the speci fi c gravi ty of the el ectrol yte
wi l l gradual l y ri se.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1 C/30 F) BATTERY.
THE BATTERY MAY ARC INTERNALLY AND
EXPLODE. PERSONAL INJURY AND/OR VEHICLE
DAMAGE MAY RESULT.
BATTERY
(1) Turn the i gni ti on swi tch to the Off posi ti on.
Make sure al l el ectri cal accessori es are turned off.
(2) Loosen the cabl e termi nal cl amps and di scon-
nect both battery cabl es, negati ve cabl e fi rst. I f nec-
essary, use a pul l er to remove the termi nal cl amps
from the battery posts (Fi g. 16).
(3) I nspect the cabl e termi nal cl amps for corrosi on
and damage. Remove any corrosi on usi ng a wi re
brush or a post and termi nal cl eani ng tool , and a
sodi um bi carbonate (baki ng soda) and warm water
cl eani ng sol uti on (Fi g. 17). Repl ace any cabl e that
has damaged or deformed termi nal cl amps.
Charge Rate
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
Battery Charging Timetable
Charging
Amperage
5
Amperes
10
Amperes
20
Amperes
Open Circuit
Voltage
Hours Charging at 21C (70F)
12.25 to 12.39 6 hours 3 hours 1.5 hours
12.00 to 12.24 8 hours 4 hours 2 hours
11.95 to 11.99 12 hours 6 hours 3 hours
10.00 to 11.94 14 hours 7 hours 3.5 hours
less than 10.00 See Charging Completely
Discharged Battery
Fig. 16 Remove Battery Terminal Clamp - Typical
BATTERY BATTERY TERMINAL PULLER
Fig. 17 Clean Battery Cable Terminal Clamp- Typical
TERMINAL BRUSH BATTERY CABLE TEST INDICA- TOR
8A - 14 BATTERY ZG
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(4) Remove the battery hol ddowns and remove the
battery from the vehi cl e (Fi g. 18).
(5) I nspect the battery tray and the hol ddowns for
corrosi on or damage. Remove any corrosi on usi ng a
wi re brush and a sodi um bi carbonate (baki ng soda)
and warm water cl eani ng sol uti on. Pai nt any exposed
bare metal and repl ace any damaged parts.
(6) I nspect the battery case for cracks or other
damage that coul d resul t i n el ectrol yte l eaks. Al so,
check the battery termi nal posts for l ooseness. Bat-
teri es wi th damaged cases or l oose posts must be
repl aced.
(7) Check the el ectrol yte l evel i n the battery. Use a
putty kni fe or another sui tabl e wi de fl at-bl aded tool
to pry the cel l caps off (Fi g. 19). Do not use a screw-
dri ver. Add di sti l l ed water to each cel l unti l the l i q-
ui d reaches the bottom of the vent wel l . DO NOT
OVERFI LL.
(8) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass for an i ndi cati on of the battery condi ti on. I f the
battery i s di scharged, charge as requi red. See the
Bui l t-I n Test I ndi cator and the Battery Chargi ng pro-
cedures i n thi s group for more i nformati on.
(9) I f the battery i s to be rei nstal l ed, cl ean the out-
si de of the battery case and the top cover wi th a
sodi um bi carbonate (baki ng soda) and warm water
cl eani ng sol uti on to remove any aci d fi l m (Fi g. 20).
Ri nse the battery wi th cl ean water. Ensure that the
cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, see the Battery Rati ngs and Cl assi fi cati ons
chart i n Speci fi cati ons at the back of thi s group. Con-
fi rm that the repl acement battery i s the correct si ze
and has the correct rati ngs for the vehi cl e.
(10) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 21).
(11) Posi ti on the battery i n the tray. Ensure that
the posi ti ve and negati ve termi nal posts are correctl y
posi ti oned. The cabl e termi nal cl amps must reach the
correct battery post wi thout stretchi ng the cabl es
(Fi g. 22).
(12) Loosel y i nstal l the battery hol ddown hard-
ware. Ensure that the battery base i s correctl y posi -
ti oned i n the tray, then ti ghten the hol ddowns to 2.2
Nm (20 i n. l bs.).
CAUTION: Be certain that the battery cables are
connected to the correct battery terminals. Reverse
polarity may damage electrical components.
(13) I nstal l and ti ghten the battery posi ti ve cabl e
termi nal cl amp. Then i nstal l and ti ghten the nega-
Fig. 18 Battery Holddowns
BOLT HOLDDOWN THERMO- GUARD BATTERY TRAY SCREW WHEELHOUSE EXTENSION TEMPERATURE SENSOR FENDER INNER SHIELD SCREW FWD
Fig. 19 Removing Cell Caps - Typical
PUTTY KNIFE
ZG BATTERY 8A - 15
ti ve cabl e termi nal cl amp. Ti ghten both cabl e termi -
nal cl amp bol ts to 8.5 Nm (75 i n. l bs.).
(14) Appl y a thi n coati ng of petrol eum jel l y or
chassi s grease to the exposed surfaces of the cabl e
termi nal cl amps and battery termi nal posts.
Fig. 20 Clean Battery - Typical
TEST INDICA- TOR BATTERY CLEANING BRUSH WARM WATER AND BAKING SODA SOLU- TION
Fig. 21 Clean Battery Terminal Post - Typical
BATTERY TEST INDI- CATOR TERMINAL BRUSH BATTERY CABLE
Fig. 22 Battery Cables
NEGATIVE CABLE
POWER DISTRIBUTION CEN- TER
8A - 16 BATTERY ZG
SPECIFICATIONS
BATTERY
Battery Classifications and Ratings
Engine
BCI Group
Size Classi-
fication
(*DIN)
Cold Crank-
ing Amper-
age
Reserve
Capacity
Ampere-
Hours
Load Test
Amperage
Gasoline 34 (*H6) 600 120 Minutes 66 300
Diesel (*H7) 700 135 Minutes 63 350
*DIN is a European specification and is used to identify the size of batteries installed in vehicles that are built
outside of North America.
ZG BATTERY 8A - 17
STARTING SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
COLD CRANKING TEST . . . . . . . . . . . . . . . . . . 5
CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . 7
FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . 5
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . 11
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 11
GENERAL INFORMATION
OVERVIEW
ods, to the more sophi sti cated On-Board Di agnosti cs
INTRODUCTION
The starti ng system consi sts of:
Battery
Starter rel ay
Starter wi th an i ntegral sol enoi d
I gni ti on swi tch
Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
Wi re harness and connecti ons.
Thi s group covers di agnosi s of the compl ete start-
i ng system, except the battery. However, thi s group
onl y covers servi ce procedures for the starter and
starter rel ay. Servi ce procedures for other starti ng
system components can be l ocated as fol l ows:
Battery - refer to Group 8A - Battery for the
di agnosti c and servi ce procedures
I gni ti on swi tch - refer to Group 8D - I gni ti on
Systems for the servi ce procedures
Cl utch pedal posi ti on swi tch - refer to Group 6 -
Cl utch for the servi ce procedures
Park/neutral posi ti on swi tch - refer to Group 21
- Transmi ssi on for the servi ce procedures
Wi re harness and connecti ons - refer to Group
8W - Wi ri ng Di agrams for the servi ce procedures.
ZG STARTING SYSTEMS 8B - 1
STARTING SYSTEM
The starti ng system components form two separate
ci rcui ts. A hi gh-amperage feed ci rcui t that feeds the
starter between 150 and 350 amperes, and a l ow-am-
perage control ci rcui t that operates on l ess than 20
amperes.
I f the vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, battery vol tage i s suppl i ed through the l ow-
amperage control ci rcui t to the coi l battery termi nal
of the starter rel ay when the i gni ti on swi tch i s
turned to the Start posi ti on. The park/neutral posi -
ti on swi tch i s i nstal l ed i n seri es between the starter
rel ay coi l ground termi nal and ground. Thi s normal l y
open swi tch prevents the starter rel ay from bei ng
energi zed unl ess the automati c transmi ssi on gear
sel ector i s i n the Neutral or Park posi ti ons.
I f the vehi cl e i s equi pped wi th a manual transmi s-
si on, i t has a cl utch pedal posi ti on swi tch i nstal l ed i n
seri es between the i gni ti on swi tch and the coi l bat-
tery termi nal of the starter rel ay. Thi s normal l y open
swi tch prevents the starter rel ay from bei ng ener-
gi zed unl ess the cl utch pedal i s depressed, preventi ng
starter operati on whi l e the cl utch di sc and the fl y-
wheel are engaged. The starter rel ay coi l ground ter-
mi nal i s al ways grounded on vehi cl es wi th a manual
transmi ssi on.
When the starter rel ay coi l i s energi zed, the nor-
mal l y open rel ay contacts cl ose. The rel ay contacts
connect the rel ay common feed termi nal to the rel ay
normal l y open termi nal . The cl osed rel ay contacts
energi ze the starter sol enoi d coi l wi ndi ngs.
The energi zed sol enoi d pul l -i n coi l pul l s i n the sol e-
noi d pl unger. The sol enoi d pl unger pul l s the shi ft
l ever i n the starter. Thi s engages the starter overrun-
ni ng cl utch and pi ni on gear wi th the starter ri ng
gear on the automati c transmi ssi on torque converter
(5.2L/5.9L engi ne), the automati c transmi ssi on
torque converter dri ve pl ate (4.0L engi ne), or the
manual transmi ssi on fl ywheel .
As the sol enoi d pl unger reaches the end of i ts
travel , the sol enoi d contact di sc compl etes the hi gh-
amperage starter feed ci rcui t and energi zes the sol e-
noi d pl unger hol d-i n coi l . Current now fl ows between
the sol enoi d battery termi nal and the starter motor,
energi zi ng the starter.
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter from damage by al l owi ng the starter
pi ni on gear to spi n faster than the pi ni on shaft.
When the dri ver rel eases the i gni ti on swi tch to the
On posi ti on, the starter rel ay coi l i s de-energi zed.
Thi s causes the rel ay contacts to open. When the
rel ay contacts open, the starter sol enoi d pl unger
hol d-i n coi l i s de-energi zed.
When the sol enoi d pl unger hol d-i n coi l i s de-ener-
gi zed, the sol enoi d pl unger return spri ng returns the
pl unger to i ts rel axed posi ti on. Thi s causes the con-
tact di sc to open the starter feed ci rcui t, and the shi ft
l ever to di sengage the overrunni ng cl utch and pi ni on
gear from the starter ri ng gear.
STARTER
The starter motor i ncorporates several features to
create a rel i abl e, effi ci ent, compact, and l i ghtwei ght
uni t. A pl anetary gear system (i ntermedi ate trans-
mi ssi on) i s used between the el ectri c motor and the
pi ni on gear. Thi s feature makes i t possi bl e to reduce
the di mensi ons of the starter. At the same ti me, i t
al l ows hi gher armature rotati onal speed and del i vers
i ncreased torque through the pi ni on gear to the
starter ri ng gear on the automati c transmi ssi on
torque converter or torque converter dri ve pl ate, or
on the manual transmi ssi on fl ywheel .
The use of a permanent magnet fi el d al so reduces
the si ze and wei ght of the starter. The permanent
magnet fi el d consi sts of four hi gh-strength perma-
nent magnets. The magnets are al i gned accordi ng to
thei r pol ari ty, and are permanentl y mounted i n the
starter fi el d frame.
The starter motors for al l engi nes are acti vated by
a sol enoi d mounted to the overrunni ng cl utch hous-
i ng. However, the starter motor and sol enoi d are ser-
vi ced onl y as a compl ete assembl y. I f ei ther
component i s faul ty or damaged, the enti re starter
assembl y must be repl aced.
CAUTION:
Permanent magnet starters are highly sensi-
tive to hammering, shocks, and external pressure.
The permanent magnets may be damaged and the
starter rendered unserviceable, if subjected to any
of these conditions.
The starter motor must not be clamped in a
vise by the starter field frame. Doing so may dam-
age the permanent magnets. The starter should
only be clamped by the mounting flange.
Do not connect the starter motor incorrectly
when testing. Reverse polarity may damage the per-
manent magnets and render the starter unservice-
able.
STARTER RELAY
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO) mi cro-rel ay. The termi nal desi g-
nati ons and functi ons are the same as a conventi onal
I SO rel ay. However, the mi cro-rel ay termi nal ori enta-
ti on (or footpri nt) i s di fferent, the current 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.
8B - 2 STARTING SYSTEMS ZG
The starter rel ay i s a el ectromechani cal devi ce that
swi tches battery current to the pul l -i n coi l of the
starter sol enoi d when the i gni ti on swi tch i s turned to
the Start posi ti on. See the Di agnosi s and Testi ng sec-
ti on of thi s group for more i nformati on on the opera-
ti on of the starter rel ay.
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC), i n the engi ne compartment. Refer
to the PDC l abel for rel ay i denti fi cati on and l ocati on.
The starter rel ay cannot be repai red and, i f faul ty
or damaged, i t must be repl aced.
STARTING SYSTEM
For ci rcui t descri pti ons and di agrams, refer to
8W-21 - Starti ng System i n Group 8W - Wi ri ng Di a-
grams.
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.
INSPECTION
Before removi ng any uni t from the starti ng system
for repai r or di agnosi s, perform the fol l owi ng i nspec-
ti ons:
Battery - Vi sual l y i nspect the battery for i ndi -
cati ons of physi cal damage and l oose or corroded
cabl e connecti ons. Determi ne the state-of-charge and
cranki ng capaci ty of the battery. Charge or repl ace
the battery, i f requi red. Refer to Group 8A - Battery
Ignition Switch - Vi sual l y i nspect the i gni ti on
swi tch for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons.
Clutch Pedal Position Switch - Vi sual l y
i nspect the cl utch pedal posi ti on swi tch for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
harness connecti ons.
Park/Neutral Position Switch - Vi sual l y
i nspect the park/neutral posi ti on swi tch for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
Starter Relay - Vi sual l y i nspect the starter
rel ay for i ndi cati ons of physi cal damage and l oose or
corroded wi re harness connecti ons.
Starter - Vi sual l y i nspect the starter for i ndi -
cati ons of physi cal damage and l oose or corroded wi re
Starter Solenoid - Vi sual l y i nspect the starter
sol enoi d for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons.
Wiring - Vi sual l y i nspect the wi re harness for
damage. Repai r or repl ace any faul ty wi ri ng, as
requi red.
Starting System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO ENGAGE. 1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Park/Neutral position switch (auto
trans) faulty or misadjusted.
6. Clutch pedal position switch (man
trans) faulty.
7. Starter solenoid faulty.
8. Starter assembly faulty.
1. Refer to Group 8A - Battery.
Charge or replace battery, if
required.
2. See Cold Cranking Test, in this
group. Test and repair feed and/or
control circuits, if required.
3. See Relay Test, in this group.
Replace relay, if required.
4. See Ignition Switch Test, in this
group. Replace switch, if required.
5. See Park/Neutral Position Switch
Test, in this group. Replace switch, if
required.
6. See Clutch Pedal Position Switch
Test, in this group. Replace switch, if
required.
7. See Solenoid Test, in this Group.
Replace starter assembly, if
required.
8. If all other starting system
components and circuits check OK,
replace starter assembly.
STARTER ENGAGES, FAILS TO
TURN ENGINE.
1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
4. Engine seized.
1. Refer to Group 8A - Battery.
Charge or replace battery, if
required.
2. See Cold Cranking Test, in this
group. Test and repair feed and/or
control circuits, if required.
4. Refer to Group 9 - Engine, for
diagnostic and service procedures.
STARTER ENGAGES, SPINS
OUT BEFORE ENGINE STARTS.
1. Broken teeth on starter ring gear.
1. Remove starter as described in
this group. Inspect ring gear and
replace, if required.
STARTER DOES NOT
DISENGAGE.
1. Starter improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
1. Install starter as described in this
group. Tighten starter mounting
hardware to correct torque
specifications.
2. See Relay Test, in this group.
Replace relay, if required.
3. See Ignition Switch Test, in this
group. Replace switch, if required.
COLD CRANKING TEST
grams. The battery must be ful l y-charged and l oad-
tested before proceedi ng. Refer to Group 8A - Battery
(1) Connect a sui tabl e vol t-ampere tester to the
battery termi nal s (Fi g. 1). Refer to the operati ng
i nstructi ons provi ded wi th the tester bei ng used.
(2) Ful l y engage the parki ng brake.
(3) I f the vehi cl e i s equi pped wi th an automati c
pedal .
(4) Veri fy that al l l amps and accessori es are
turned off.
(5) Unpl ug the Automati c ShutDown (ASD) rel ay
to prevent a gasol i ne engi ne from starti ng. The ASD
(6) Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Note the cranki ng vol tage and current
(amperage) draw.
(a) I f the vol tage reads bel ow 9.6 vol ts, remove
the starter for bench testi ng. I f the starter bench
test i s OK, refer to Group 9 - Engi ne for further
di agnosi s of the engi ne. I f the starter bench test i s
not OK, repl ace the faul ty starter.
(b) I f the vol tage reads above 9.6 vol ts and the
current (amperage) draw reads bel ow speci fi ca-
ti ons, see the Feed Ci rcui t Test procedures i n thi s
group.
(c) I f the vol tage reads 12.5 vol ts or greater and
the starter does not turn, see the Control Ci rcui t
Test procedures i n thi s group.
(d) I f the vol tage reads 12.5 vol ts or greater and
the starter turns very sl owl y, see the Feed Ci rcui t
Test procedures i n thi s group.
NOTE: A cold engine will increase the starter cur-
rent (amperage) draw reading, and reduce the bat-
tery voltage reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n the
hi gh-amperage ci rcui t. For ci rcui t descri pti ons and
di agrams, refer to 8W-21 - Starti ng System i n Group
8W - Wi ri ng Di agrams.
When performi ng these tests, i t i s i mportant to
remember that the vol tage drop i s gi vi ng an i ndi ca-
ti on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached.
Example: When testi ng the resi stance of the bat-
tery posi ti ve cabl e, touch the vol tmeter l eads to the
battery posi ti ve cabl e cl amp and the cabl e connector
at the starter sol enoi d. I f you probe the battery pos-
i ti ve termi nal post and the cabl e connector at the
starter sol enoi d, you are readi ng the combi ned vol t-
age drop i n the battery posi ti ve cabl e cl amp-to-termi -
nal post connecti on and the battery posi ti ve cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng the
tests, be certai n the fol l owi ng procedures are accom-
pl i shed:
Fig. 1 Volts-Amps Tester Connections - Typical
POSITIVE CLAMP NEGATIVE CLAMP INDUCTION AMMETER CLAMP
Engine
Battery i s ful l y-charged. Refer to Group 8A -
Battery for more i nformati on.
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
pedal .
Unpl ug the Automati c ShutDown (ASD) rel ay to
prevent a gasol i ne engi ne from starti ng. The ASD
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e cl amp (Fi g. 4). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor contact between
the cabl e cl amp and the termi nal post.
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
cl amp (Fi g. 5). Rotate and hol d the i gni ti on swi tch i n
the Start posi ti on. Observe the vol tmeter. I f vol tage
i s detected, correct the poor contact between the
cabl e cl amp and the termi nal post.
battery posi ti ve termi nal post and the starter sol e-
noi d battery termi nal stud (Fi g. 6). Rotate and hol d
ti ghten the battery cabl e connecti on at the sol enoi d.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
battery negati ve termi nal post and a good cl ean
ground on the engi ne bl ock (Fi g. 7). Rotate and hol d
ti ghten the battery negati ve cabl e attachment on the
engi ne bl ock. Repeat the test. I f the readi ng i s sti l l
above 0.2 vol t, repl ace the faul ty battery negati ve
cabl e.
the starter housi ng. Connect the negati ve l ead of the
vol tmeter to the battery negati ve termi nal post (Fi g.
8). Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Observe the vol tmeter. I f the readi ng i s
Engine
Fig. 4 Test Battery Negative ConnectionResistance -
Typical
VOLTMETER BATTERY
Fig. 5 Test Battery Positive ConnectionResistance -
Typical
VOLTMETER BATTERY
above 0.2 vol t, correct the poor starter to engi ne
bl ock ground contact.
I f the resi stance tests detect no feed ci rcui t prob-
l ems, remove the starter and see the Sol enoi d Test
procedure i n thi s group.
CONTROL CIRCUIT TEST
grams. The starter control ci rcui t consi sts of:
Battery
Starter rel ay
Starter sol enoi d
I gni ti on swi tch
Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
Wi re harness and connecti ons.
Test procedures for these components shoul d be
performed i n the order i n whi ch they are l i sted, as
fol l ows:
SOLENOID TEST
Remove the starter as descri bed i n thi s group.
Then proceed as fol l ows:
(1) Remove the wi re from the sol enoi d fi el d coi l
termi nal .
(2) Check for conti nui ty between the sol enoi d ter-
mi nal and the fi el d coi l termi nal wi th a conti nui ty
tester (Fi g. 9). There shoul d be conti nui ty. I f OK, go
to Step 3. I f not OK, repl ace the faul ty starter assem-
bl y.
(3) Check for conti nui ty between the sol enoi d ter-
mi nal and the sol enoi d case (Fi g. 10). There shoul d
be conti nui ty. I f OK, go to Step 4. I f not OK, repl ace
the faul ty starter assembl y.
(4) Connect the sol enoi d fi el d coi l wi re to the fi el d
coi l termi nal .
(5) I nstal l the starter as descri bed i n thi s group.
Fig. 6 Test Battery Positive Cable Resistance-
Typical
BATTERY VOLTMETER STARTER MOTOR
Fig. 7 Test Ground Circuit Resistance -Typical
VOLTMETER ENGINE GROUND BATTERY
Fig. 8 Test Starter Ground - Typical
STARTER MOTOR BATTERY VOLTMETER
Fig. 9 Continuity Test Between SolenoidTerminal
and Field Coil Terminal
SOLENOID SOLENOID TERMINAL OHMMETER FIELD COIL TERMI- NAL
Fig. 10 Continuity Test Between SolenoidTerminal
and Solenoid Case
SOLENOID SOLENOID TER- MINAL OHMMETER
RELAY TEST
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC) i n the engi ne compartment. Refer
to the PDC l abel for starter rel ay i denti fi cati on and
l ocati on.
Remove the starter rel ay from the PDC 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 procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(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 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 starter sol enoi d fi el d coi l s. There shoul d be
conti nui ty between the cavi ty for rel ay termi nal 87
and the starter sol enoi d termi nal 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
starter sol enoi d as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s energi zed when
the i gni ti on swi tch i s hel d i n the Start posi ti on. On
vehi cl es wi th a manual transmi ssi on, the cl utch
pedal must be ful l y depressed for thi s test. Check for
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 Start posi ti on, and no
vol tage when the i gni ti on swi tch i s rel eased to the
On posi ti on. I f OK, go to Step 5. I f not OK wi th an
automati c transmi ssi on, check for an open or short
ci rcui t to the i gni ti on swi tch and repai r, i f requi red.
I f the ci rcui t to the i gni ti on swi tch i s OK, see the
I gni ti on Swi tch Test procedure i n thi s group. I f not
OK wi th a manual transmi ssi on, check the ci rcui t
between the rel ay and the cl utch pedal posi ti on
swi tch for an open or a short. I f the ci rcui t i s OK, see
the Cl utch Pedal Posi ti on Swi tch Test procedure i n
thi s group.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. On vehi cl es wi th an
automati c transmi ssi on, i t i s grounded through the
park/neutral posi ti on swi tch onl y when the gearshi ft
sel ector l ever i s i n the Park or Neutral posi ti ons. On
vehi cl es wi th a manual transmi ssi on, i t i s grounded
at al l ti mes. Check for conti nui ty to ground at the
cavi ty for rel ay termi nal 85. I f not OK wi th an auto-
mati c transmi ssi on, check for an open or short ci rcui t
to the park/neutral posi ti on swi tch and repai r, i f
requi red. I f the ci rcui t i s OK, see the Park/Neutral
Posi ti on Swi tch Test procedure i n thi s group. I f not
OK wi th a manual transmi ssi on, repai r the ci rcui t to
ground as requi red.
PARK/NEUTRAL POSITION SWITCH TEST
(1) Pl ace the transmi ssi on gear sel ector l ever i n
the Park posi ti on.
cabl e.
(4) Unpl ug the park/neutral posi ti on swi tch wi re
harness connector.
(5) Check for conti nui ty between the center swi tch
termi nal and a good chassi s ground. There shoul d be
conti nui ty. I f OK, go to Step 6. I f not OK, repl ace the
faul ty swi tch.
(6) Move the transmi ssi on gear sel ector l ever to
the Reverse posi ti on and check for conti nui ty
between the center swi tch termi nal and a good chas-
si s ground. There shoul d be no conti nui ty. I f not OK,
repl ace the faul ty swi tch.
CLUTCH PEDAL POSITION SWITCH TEST
The cl utch pedal posi ti on swi tch i s i ntegral to the
cl utch pedal pushrod. I t i s l ocated near the dash
panel under the i nstrument panel . The wi re harness
connector for the swi tch i s wrapped wi th foam tape.
cabl e.
(2) Unpl ug the cl utch pedal posi ti on swi tch wi re
harness connector.
Starter Relay
TERMINAL LEGEND NUMBER IDENTIFICATION COMMON FEED
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
(3) Check for conti nui ty between the two cavi ti es
i n the swi tch-hal f of the wi re harness connector wi th
the cl utch pedal rel eased. There shoul d be no conti -
nui ty. I f OK, go to Step 4. I f not OK, repl ace the
faul ty swi tch.
(4) Check for conti nui ty between the two cavi ti es
i n the swi tch-hal f of the wi re harness connector
agai n wi th the cl utch pedal depressed. There shoul d
now be conti nui ty. I f OK, see the I gni ti on Swi tch Test
procedure i n thi s group. I f not OK, repl ace the faul ty
swi tch.
IGNITION SWITCH TEST
RESTRAINT SYSTEMS BEFORE ATTEMPTING
INJURY.
cabl e.
(2) Remove the steeri ng col umn shrouds and
unpl ug the i gni ti on swi tch wi re harness connector.
Refer to Group 8D - I gni ti on Systems for the proce-
dures.
(3) Wi th the i gni ti on swi tch i n the On posi ti on,
check for conti nui ty between the two fused B(+) ter-
mi nal s of the i gni ti on swi tch (termi nal s 1 and 7).
These are the termi nal s at each end of the swi tch
connector receptacl e. There shoul d be no conti nui ty.
I f OK, go to Step 4. I f not OK, repl ace the faul ty
swi tch.
(4) Wi th the i gni ti on swi tch hel d i n the Start posi -
ti on, check for conti nui ty between the two fused B(+)
termi nal s of the i gni ti on swi tch (termi nal s 1 and 7).
There shoul d now be conti nui ty. I f not OK, repl ace
the faul ty swi tch.
STARTER
2.5L DIESEL ENGINE
cabl e.
(3) Remove the ri ght front engi ne mount i nsul ator
and brackets. Refer to Group 9 - Engi nes for the pro-
cedures.
(4) Remove the starter front support bracket (Fi g.
11).
(5) Remove the strap that secures the starter heat
shi el d and remove the heat shi el d from the starter
(Fi g. 12).
(6) Remove the three bol ts that secure the starter
mounti ng fl ange to the transmi ssi on adapter pl ate.
(7) Lower the starter far enough to access and
remove the wi re harness connecti ons from the sol e-
noi d.
(8) Remove the starter from the vehi cl e.
(9) Reverse the removal procedures to i nstal l .
Ti ghten the starter hardware as fol l ows:
Battery cabl e termi nal nut - 27 Nm (20 ft. l bs.)
Starter mounti ng bol ts - 27 Nm (20 ft. l bs.)
Front starter support bracket nuts - 10 Nm (90
i n. l bs.)
Fig. 11 Starter Mounting - 2.5L Diesel Engine
NUT (2) STARTER MOUNTING BOLT (3) MOUNTING BRACKET BOLT
Fig. 12 Starter Heat Shield Remove/Install
STRAP THICK PORTION THIN PORTION HEAT SHIELD
Front starter support bracket bol t - 47 Nm (35
ft. l bs.).
4.0L ENGINE
cabl e.
(3) Remove the battery cabl e and wi re harness
connecti on from the starter sol enoi d (Fi g. 13).
(4) Remove the front starter mounti ng bol t and the
automati c transmi ssi on oi l cool er l i ne bracket (Fi g.
14).
(5) Remove the rear starter mounti ng bol t and
l ower the starter.
Upper mounti ng bol t - 55 Nm (40 ft. l bs.)
Lower mounti ng bol t - 41 Nm (30 ft. l bs.)
Battery cabl e termi nal nut - 10 Nm (90 i n. l bs.)
Sol enoi d wi re harness termi nal nut - 6 Nm (55
i n. l bs.).
5.2L AND 5.9L ENGINE
cabl e.
(3) Remove the battery cabl e and wi re harness
connecti on from the starter sol enoi d (Fi g. 13).
(4) Remove the l ower starter mounti ng bol t and
the exhaust brace (Fi g. 15).
(5) Remove the upper starter mounti ng nut, l ock
washer, and automati c transmi ssi on oi l cool er l i ne
bracket.
(6) Move the starter towards the front of the vehi -
cl e unti l the starter gear housi ng nose cl ears the bel l -
housi ng. Then ti l t the starter nose downwards past
the exhaust pi pe.
Lower mounti ng bol t - 68 Nm (50 ft. l bs.)
Upper mounti ng nut - 68 Nm (50 ft. l bs.)
Battery cabl e termi nal nut - 10 Nm (90 i n. l bs.)
Sol enoi d wi re harness termi nal nut - 6 Nm (55
i n. l bs.).
Fig. 13 Starter Wire Harness Remove/Install- Typical
STARTER MOTOR SOLENOID
REMOVE
NUTS (2)
BATTERY FEED WIRE SOLENOID FEED WIRE
Fig. 14 Starter Remove/Install - 4.0L Engine
FWD BRACKET FRONT BOLT STARTER REAR BOLT
Fig. 15 Starter Remove/Install - 5.2L and5.9L Engine
BRACKET LOCKWASHER UPPER NUT LOWERBOLT BRACE STARTER FWD STUD
STARTER RELAY
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 16).
(3) Refer to the l abel on the PDC for starter rel ay
i denti fi cati on and l ocati on.
(4) Unpl ug the starter rel ay from the PDC.
(5) I nstal l the starter 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.
SPECIFICATIONS
STARTING SYSTEM
Fig. 16 Power Distribution Center
NEGATIVE CABLE POWER DISTRIBUTION CEN- TER POSITIVE CABLE
Starter and Solenoid
Manufacturer Bosch Mitsubishi Mitsubishi
Engine Application 2.5L Diesel 4.0L Gasoline 5.2L/5.9L Gasoline
Power Rating 2.2 Kilowatt 1.4 Kilowatt 1.4 Kilowatt
Voltage 12 Volts 12 Volts 12 Volts
Number of Fields 4 4 4
Number of Poles 4 4 4
Number of Brushes 4 4 4
Drive Type Planetary Gear
Reduction
Planetary Gear
Reduction
Planetary Gear
Reduction
Free Running Test Voltage 11.5 Volts 11.2 Volts 11.2 Volts
Free Running Test Maximum
Amperage Draw
160 Amperes 80 Amperes 80 Amperes
Free Running Test Minimum Speed 5500 rpm 2500 rpm 2500 rpm
Solenoid Closing Maximum Voltage 7.8 Volts 7.8 Volts 7.8 Volts
*Cranking Amperage Draw Test 350 Amperes 160 Amperes 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
STARTING SYSTEMS
CONTENTS
page page
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
STARTER
2.5L DIESEL ENGINE
cabl e.
(3) Remove the ri ght front engi ne mount i nsul ator
and brackets. Refer to Group 9 - Engi nes for the pro-
cedures.
(4) Remove the starter front support bracket (Fi g.
1).
(5) Remove the strap that secures the starter heat
shi el d and remove the heat shi el d from the starter
(Fi g. 2).
(6) Remove the three bol ts that secure the starter
mounti ng fl ange to the transmi ssi on adapter pl ate.
(7) Lower the starter far enough to access and
remove the wi re harness connecti ons from the sol e-
noi d.
(8) Remove the starter from the vehi cl e.
Battery cabl e termi nal nut - 27 Nm (20 ft. l bs.)
Starter mounti ng bol ts - 27 Nm (20 ft. l bs.)
Front starter support bracket nuts - 10 Nm (90
i n. l bs.)
Front starter support bracket bol t - 47 Nm (35
ft. l bs.).
STARTER RELAY
cabl e.
Center (PDC).
(3) Refer to the l abel on the PDC for starter rel ay
(4) Unpl ug the starter rel ay from the PDC.
(5) I nstal l the starter 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.
Fig. 1 Starter Mounting - 2.5L Diesel Engine
Fig. 2 Starter Heat Shield Remove/Install
SPECIFICATIONS
STARTING SYSTEM
Starter and Solenoid
Engine Application 2.5L Diesel
Power Rating 2.2 Kilowatt
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.5 Volts
Free Running Test Maximum Amperage Draw 160 Amperes
Free Running Test Minimum Speed 5500 rpm
Solenoid Closing Maximum Voltage 7.8 Volts
*Cranking Amperage Draw test 350 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
CHARGING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BATTERY TEMPERATURE SENSOR . . . . . . . . . 2
CHARGING SYSTEM OPERATION . . . . . . . . . . 1
ELECTRONIC VOLTAGE REGULATOR . . . . . . . 2
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHARGING SYSTEM RESISTANCE TESTS . . . . 3
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
CURRENT OUTPUT TEST . . . . . . . . . . . . . . . . . 3
ON-BOARD DIAGNOSTIC TEST FOR
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . 5
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
GENERATOR RATINGS . . . . . . . . . . . . . . . . . . . 7
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
OVERVIEW
ods to the more sophi sti cated On-Board Di agnosti cs
CHARGING SYSTEM OPERATION
The chargi ng system consi sts of:
Generator
El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM)
I gni ti on swi tch (refer to Group 8D, I gni ti on Sys-
tem for i nformati on)
Battery (refer to Group 8A, Battery for i nforma-
ti on)
Battery temperature sensor
Generator Lamp (i f equi pped)
Check Gauges Lamp (i f equi pped)
Vol tmeter (refer to Group 8E, I nstrument Panel
and Gauges for i nformati on)
Wi ri ng harness and connecti ons (refer to Group
8W, Wi ri ng for i nformati on)
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. When the i gni ti on swi tch i s turned to
the ON posi ti on, battery vol tage from the powertrai n
control modul e (PCM) i s suppl i ed to the generator
rotor to produce a magneti c fi el d. Thi s i s done
through one of the two fi el d termi nal s at the rear of
generator. On models of previous years, battery
voltage to this field terminal was supplied
directly from the ASD relay.
The amount of DC current produced by the gener-
ator i s control l ed by the EVR (fi el d control ) ci rcui try
contai ned wi thi n the PCM. Thi s ci rcui try i s con-
nected i n seri es wi th the second rotor fi el d termi nal
and ground.
A battery temperature sensor, l ocated i n the bat-
tery tray housi ng, i s used to sense battery tempera-
ture. Thi s temperature data, al ong wi th data from
moni tored l i ne vol tage, i s used by the PCM to vary
the battery chargi ng rate. Thi s i s done by cycl i ng the
ground path to control the strength of the rotor mag-
neti c fi el d. The PCM then compensates and regul ates
generator current output accordi ngl y.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng the
EVR (fi el d control ) ci rcui try, are moni tored by the
ZG CHARGING SYSTEM 8C - 1
el ectroni c memory for any fai l ure i t detects. Refer to
On-Board Di agnosti c Test For Chargi ng System i n
The Check Gauges Lamp moni tors: charging sys-
tem voltage, engi ne cool ant temperature and engi ne
oi l pressure. I f an extreme condi ti on i s i ndi cated, the
l amp wi l l be i l l umi nated. Thi s i s done as remi nder to
check the three gauges. The si gnal to acti vate the
l amp i s sent vi a the CCD bus ci rcui ts. The l amp i s
l ocated on the i nstrument panel . Refer to Group 8E,
I nstrument Panel and Gauges for addi ti onal i nforma-
ti on.
GENERATOR
The generator i s bel t-dri ven by the engi ne usi ng a
serpenti ne type dri ve bel t. I t i s servi ced onl y as a
compl ete assembl y. I f the generator fai l s for any rea-
son, the enti re assembl y must be repl aced.
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
The Y type stator wi ndi ng connecti ons del i ver the
i nduced AC current to 3 posi ti ve and 3 negati ve
di odes for recti fi cati on. From the di odes, recti fi ed DC
current i s del i vered to the vehi cl e el ectri cal system
through the generator battery and ground termi nal s.
Al though the generators appear the same exter-
nal l y, di fferent generators wi th di fferent output rat-
i ngs are used on thi s vehi cl e. Be certai n that the
repl acement generator has the same output rati ng
and part number as the ori gi nal uni t. Refer to Gen-
erator Rati ngs i n the Speci fi cati ons secti on at the
back of thi s group for amperage rati ngs and part
numbers.
Noi se emi tti ng from the generator may be caused
by: worn, l oose or defecti ve beari ngs; a l oose or defec-
ti ve dri ve pul l ey; i ncorrect, worn, damaged or mi sad-
justed fan dri ve bel t; l oose mounti ng bol ts; a
mi sal i gned dri ve pul l ey or a defecti ve stator or di ode.
BATTERY TEMPERATURE SENSOR
The battery temperature sensor i s used to deter-
mi ne the battery temperature and control battery
chargi ng rate. Thi s temperature data, al ong wi th
data from moni tored l i ne vol tage, i s used by the PCM
to vary the battery chargi ng rate. System vol tage wi l l
be hi gher at col der temperatures and i s gradual l y
reduced at warmer temperatures.
ELECTRONIC VOLTAGE REGULATOR
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the Powertrai n Control
Modul e (PCM). The EVR i s not servi ced separatel y. I f
repl acement i s necessary, the PCM must be repl aced.
Operation: The amount of DC current produced
by the generator i s control l ed by EVR ci rcui try con-
tai ned wi thi n the PCM. Thi s ci rcui try i s connected i n
seri es wi th the generators second rotor fi el d termi nal
and i ts ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage and bat-
tery temperature (refer to Battery Temperature Sen-
sor for more i nformati on). I t then compensates and
regul ates generator current output accordi ngl y. Al so
see Chargi ng System Operati on for addi ti onal i nfor-
mati on.
CHARGING SYSTEM
The fol l owi ng procedures may be used to di agnose
the chargi ng system i f:
the generator l amp (i f equi pped) i s i l l umi nated
wi th the engi ne runni ng
the vol tmeter (i f equi pped) does not regi ster
properl y
an undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
accessori es bei ng l eft on wi th the engi ne not
runni ng
a faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. See I gni ti on-Off Draw Test
i n Group 8A, Battery for more i nformati on.
INSPECTION
To perform a compl ete test of the chargi ng system,
refer to the appropri ate Powertrai n Di agnosti c Proce-
dures servi ce manual and the DRB scan tool . Per-
form the fol l owi ng i nspecti ons before attachi ng the
scan tool .
(1) I nspect the battery condi ti on. Refer to Group
8A, Battery for procedures.
(2) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
(3) I nspect al l fuses i n both the fusebl ock and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
8C - 2 CHARGING SYSTEM ZG
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n Group 7, Cool i ng Sys-
tem.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to Group 7, Cool i ng System for i nformati on.
(7) I nspect connecti ons at generator fi el d, battery
output, and ground termi nal s. Al so check ground con-
necti on at engi ne. They shoul d al l be cl ean and ti ght.
Repai r as requi red.
CHARGING SYSTEM RESISTANCE TESTS
These tests wi l l show the amount of vol tage drop
across the generator output wi re, from the generator
output (B+) termi nal to the battery posi ti ve post.
They wi l l al so show the amount of vol tage drop from
the ground (-) termi nal on the generator to the bat-
tery negati ve post. A typi cal generator wi ri ng har-
ness i s shown i n (Fi g. 1). Wi ri ng harness routi ng as
shown i n (Fi g. 1) may be sl i ghtl y di fferent dependi ng
on vehi cl e model and/or engi ne. Refer to Group 8W,
Wi ri ng Di agrams for addi ti onal i nformati on.
A vol tmeter wi th a 018 vol t DC scal e shoul d be
used for these tests. By reposi ti oni ng the vol tmeter
test l eads, the poi nt of hi gh resi stance (vol tage drop)
can easi l y be found.
PREPARATION
(1) Before starti ng test, make sure battery i s i n
good condi ti on and i s ful l y-charged. See Group 8A,
(2) Check condi ti on of battery cabl es at battery.
Cl ean i f necessary.
(3) Start the engi ne and al l ow i t to reach normal
operati ng temperature.
(4) Shut engi ne off.
(5) Connect an engi ne tachometer.
TEST
(1) Start engi ne.
(2) Pl ace heater bl ower i n hi gh posi ti on.
(3) Turn on headl amps and pl ace i n hi gh-beam
posi ti on.
(4) Turn vehi cl e i nteri or l amps on.
(5) Bri ng engi ne speed up to 2400 rpm and hol d.
(6) Testi ng (+) ci rcui try:
(a) Touch the negati ve l ead of vol tmeter di rectl y
to battery posi ti ve post.
(b) Touch the posi ti ve l ead of vol tmeter to the
B+ output termi nal stud on the generator (not the
termi nal mounti ng nut). Vol tage shoul d be no
hi gher than 0.6 vol ts. I f vol tage i s hi gher than 0.6
vol ts, touch test l ead to termi nal mounti ng stud
nut and then to the wi ri ng connector. I f vol tage i s
now bel ow 0.6 vol ts, l ook for di rty, l oose or poor
connecti on at thi s poi nt. Al so check condi ti on of the
generator output wi re-to-battery bul l et connector
(i f equi pped). Refer to Group 8, Wi ri ng for connec-
tor l ocati on. A vol tage drop test may be performed
at each (+) connecti on i n thi s ci rcui t to l ocate the
excessi ve resi stance.
(7) Testi ng (-) ci rcui try:
(a) Touch the negati ve l ead of vol tmeter di rectl y
to battery negati ve post.
(b) Touch the posi ti ve l ead of vol tmeter to the
ground termi nal stud on the generator case (not
the termi nal mounti ng nut). Vol tage shoul d be no
hi gher than 0.3 vol ts. I f vol tage i s hi gher than 0.3
vol ts, touch test l ead to termi nal mounti ng stud
nut and then to the wi ri ng connector. I f vol tage i s
now bel ow 0.3 vol ts, l ook for di rty, l oose or poor
connecti on at thi s poi nt. A vol tage drop test may be
performed at each (-) connecti on i n thi s ci rcui t to
l ocate the excessi ve resi stance. Thi s test can al so
be performed between the generator case and the
engi ne. I f test vol tage i s hi gher than 0.3 vol ts,
check for corrosi on at generator mounti ng poi nts or
l oose generator mounti ng.
CURRENT OUTPUT TEST
The current output test wi l l determi ne i f the
chargi ng system can del i ver i ts mi ni mum test cur-
rent (amperage) output. Refer to the Speci fi cati ons
secti on at the end of thi s group for mi ni mum test
current (amperage) requi rements.
The fi rst part of thi s test (Test 1) wi l l determi ne
the combi ned amperage output of both the generator
Fig. 1 Generator Terminals (Typical Wiring Harness
Shown)
GROUND TERMINAL
B+ (OUTPUT TERMINAL)
FIELD TERMINALS
and the El ectroni c Vol tage Regul ator (EVR) ci rcui try.
The second part of thi s test (Test 2) wi l l determi ne
onl y generator amperage and will not i ncl ude anal -
ysi s of EVR ci rcui try. EVR ci rcui try i s l ocated wi thi n
the Powertrai n Control Modul e (PCM). To test vol t-
age regul ator ci rcui try, refer to the appropri ate Pow-
ertrai n Di agnosti c Procedures servi ce manual .
PREPARATION
(1) Determi ne i f any Di agnosti c Troubl e Codes
(DTCs) exi st. To determi ne a DTC, refer to On-Board
Di agnosti cs i n thi s group. For repai r, refer to the
appropri ate Powertrai n Di agnosti c Procedures man-
ual .
(2) Before starti ng test, make sure battery i s i n
good condi ti on and i s ful l y-charged. See Group 8A,
(3) Check condi ti on of battery cabl es at battery.
Cl ean i f necessary.
(4) Perform the previ ous Chargi ng System Resi s-
tance Tests (vol tage drop tests). Thi s wi l l ensure
cl ean and ti ght generator/battery el ectri cal connec-
ti ons.
(5) Be sure the generator dri ve bel t i s properl y
tensi oned. Refer to Group 7, Cool i ng System for
i nformati on.
(6) A vol t/amp tester equi pped wi th both a battery
l oad control (carbon pi l e rheostat) and an i nducti ve-
type pi ckup cl amp (ammeter probe) wi l l be used for
thi s test. Refer to operati ng i nstructi ons suppl i ed
wi th tester. When usi ng a tester equi pped wi th an
i nducti ve-type cl amp, removal of wi ri ng at the gener-
ator wi l l not be necessary.
(7) Start the engi ne and al l ow i t to reach operati ng
temperature.
(9) Turn off al l el ectri cal accessori es and al l vehi cl e
l i ghti ng.
(10) Connect the vol t/amp tester l eads to the bat-
tery. Be sure the carbon pi l e rheostat control i s i n the
OPEN or OFF posi ti on before connecti ng l eads. See
Load Test i n Group 8A, Battery for more i nformati on.
Al so refer to the operati ng i nstructi ons suppl i ed wi th
test equi pment.
(11) Connect the i nducti ve cl amp (ammeter probe).
Refer to the operati ng i nstructi ons suppl i ed wi th test
equi pment.
(12) I f vol t/amp tester i s not equi pped wi th an
engi ne tachometer, connect a separate tachometer to
the engi ne.
TEST 1
(1) Perform the previ ous test Preparati on.
(3) Start engi ne.
(4) Bri ng engi ne speed to 2500 rpm.
(5) Wi th engi ne speed hel d at 2500 rpm, sl owl y
adjust the rheostat control (l oad) on the tester to
obtai n the hi ghest amperage readi ng. Do not al l ow
vol tage to drop bel ow 12 vol ts. Record the readi ng.
This load test must be performed within 15 sec-
onds to prevent damage to test equipment. On
certai n brands of test equi pment, thi s l oad wi l l be
appl i ed automati cal l y. Refer to the operati ng manual
suppl i ed wi th test equi pment.
(6) The ammeter readi ng must meet the Mi ni mum
Test Amps speci fi cati ons as di spl ayed i n the Genera-
tor Rati ngs chart. Thi s can be found i n the Speci fi ca-
ti ons secti on at the end of thi s group. A l abel stati ng
a part reference number i s attached to the generator
case. On some engi nes thi s l abel may be l ocated on
the bottom of the case. Compare thi s reference num-
ber to the Generator Rati ngs chart.
(7) Rotate the l oad control to the OFF posi ti on.
(8) Conti nue hol di ng engi ne speed at 2500. I f EVR
ci rcui try i s OK, amperage shoul d drop bel ow 1520
amps. Wi th al l el ectri cal accessori es and vehi cl e
l i ghti ng off, thi s coul d take several mi nutes of engi ne
operati on. I f amperage di d not drop, refer to the
ual for testi ng.
(9) Remove vol t/amp tester.
I f mi ni mum amperage coul d not be met, proceed to
Test 2. Thi s test wi l l determi ne i f the generator i s
faul ty, or i f EVR ci rcui try i s defecti ve.
TEST 2
(1) Perform the previ ous test preparati on.
(3) Connect one end of a jumper wi re to a good
ground. Connect the other end of jumper wi re to the
generator fi el d dri ver (-) termi nal . The 2 fi el d termi -
nal s (+ and -) are l ocated on the back of the genera-
tor (Fi g. 1). To l ocate and i denti fy the (-) termi nal
and ci rcui t, refer to Group 8W, Wi ri ng Di agrams.
Another way to i denti fy the (-) termi nal i s to start
the engi ne and measure vol tage at both fi el d termi -
nal s. The (+) termi nal wi l l show battery vol tage
(12.514.5 vol ts). The (-) termi nal wi l l show 35 vol ts
l ess than battery vol tage.
CAUTION: Do not connect the jumper ground wire
to the generator field source (+) field terminal. Dam-
age to electrical system components may result.
Connecti ng the jumper wi re wi l l remove the vol t-
age regul ator ci rcui try from the test. I t wi l l al so gen-
erate a Di agnosti c Troubl e Code (DTC).
(4) Start engi ne. Immediately after starti ng,
reduce engi ne speed to i dl e. Thi s wi l l prevent any
el ectri cal accessory damage from hi gh vol tage.
(5) Adjust carbon pi l e rheostat (l oad) and engi ne
speed i n sl ow i ncrements unti l a speed of 1250 rpm,
and a vol tmeter readi ng of 15 vol ts i s obtai ned.
I mmedi atel y record ammeter readi ng. Do not appl y
l oad to system l onger than 15 seconds as damage to
test equi pment may resul t.
CAUTION: When adjusting rheostat load, do not
allow voltage to rise above 16 volts. Damage to the
battery and electrical system components may
result.
(6) The ammeter readi ng must meet the Mi ni mum
Test Amps speci fi cati ons as di spl ayed i n the Genera-
tor Rati ngs chart. Thi s can be found i n the Speci fi ca-
ti ons secti on at the end of thi s group. A l abel stati ng
a part reference number i s attached to the generator
case. On some engi nes thi s l abel may be l ocated on
the bottom of the case. Compare thi s reference num-
ber to the Generator Rati ng chart.
(7) Remove vol t/amp tester.
(8) Remove jumper wi re.
(9) Use the DRB scan tool to erase the DTC. Refer
to the DRB screen for procedures.
RESULTS
I f amp readi ng meets speci fi cati ons i n Test 2,
generator i s OK.
I f amp readi ng i s l ess than speci fi ed i n Test 2,
and wi re resi stance (vol tage drop) tests were OK, the
generator shoul d be repl aced. Refer to Removal and
I nstal l ati on i n thi s group for procedures.
I f Test 2 resul ts were OK, but Test 1 resul ts
were not, the probl em i s i n EVR ci rcui try. Refer to
ual for di agnosi s.
To perform a compl ete test of thi s sensor and i ts
ci rcui try, refer to the appropri ate Powertrai n Di ag-
nosti c Procedures manual . To test the sensor onl y,
refer to the fol l owi ng:
(1) The sensor i s l ocated under the battery and i s
attached to the battery tray (Fi g. 2). A two-wi re pi g-
tai l harness i s attached di rectl y to the sensor. The
opposi te end of thi s harness connects the sensor to
the engi ne wi ri ng harness.
(2) Di sconnect the two-wi re pi gtai l harness from
the engi ne harness.
(3) Attach ohmmeter l eads to the wi re termi nal s of
the pi gtai l harness.
(4) At room temperature of 25 C (7580 F), an
ohmmeter readi ng of 9,000 (9K) to 11,000 (11K) ohms
shoul d be observed.
(5) I f readi ng i s above or bel ow the speci fi cati on,
repl ace the sensor.
(6) Refer to the Removal and I nstal l ati on secti on
for procedures.
ON-BOARD DIAGNOSTIC TEST FOR CHARGING
SYSTEM
The Powertrai n Control Modul e (PCM) moni tors
cri ti cal i nput and output ci rcui ts of the chargi ng sys-
tem, maki ng sure they are operati onal . A Di agnosti c
Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some ci rcui ts are checked conti nu-
ousl y and some are checked onl y under certai n con-
di ti ons.
For DTC i nformati on, refer to Di agnosti c Troubl e
Codes i n Group 25, Emi ssi on Control System. Thi s
wi l l i ncl ude a compl ete l i st of DTCs i ncl udi ng DTCs
for the chargi ng system.
GENERATOR
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
(1) Di sconnect negati ve battery cabl e.
(2) Remove generator dri ve bel t. Refer to Group 7,
Cool i ng System for procedure.
(3) Remove generator pi vot and mounti ng bol ts/nut
(Fi g. 3) or (Fi g. 4). Posi ti on generator for access to
wi re connectors.
(4) Remove nuts from harness hol ddown, battery
termi nal , ground termi nal and 2 fi el d termi nal s.
Remove wi re connectors. A typi cal generator wi ri ng
harness i s shown i n (Fi g. 5). Wi ri ng harness routi ng
as shown may be sl i ghtl y di fferent dependi ng on
vehi cl e model and/or engi ne. Refer to Group 8W, Wi r-
i ng Di agrams for addi ti onal i nformati on.
(5) Remove generator.
Fig. 2 Battery Temperature Sensor
ENGINE WIR- ING HARNESS BATTERY TEMPERATURE SENSOR SENSOR HARNESS BATTERYTRAY
(6) Reverse removal procedures to i nstal l . Ti ghten
generator hardware as fol l ows:
Generator mounti ng bol t 5.2L/5.9L engi nes - 41
Nm (30 ft. l bs.)
Generator pi vot bol t/nut 5.2L/5.9L engi nes - 41
Nm (30 ft. l bs.)
Generator mounti ng bol t 4.0L engi ne - 55 Nm
(41 ft. l bs.)
Generator pi vot bol t/nut 4.0L engi ne - 55 Nm
(41 ft. l bs.)
Battery termi nal nut - 8.5 Nm (75 i n. l bs.)
Ground termi nal nut - 8.5 Nm (75 i n. l bs.)
Harness hol ddown nut - 8.5 Nm (75 i n. l bs.)
Fi el d termi nal nuts - 2.8 Nm (25 i n. l bs.)
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.
Fig. 3 Remove/Install Generator5.2L/5.9LEngine
GENERATOR MOUNTINGBOLTS
Fig. 4 Remove/Install Generator4.0LEngine
UPPER MOUNTING BRACKET
GENERATOR
Fig. 5 Remove/Install Generator Connectors
Typical
GROUND (-) TERMINAL WIRE HARNESS HOLDDOWN (B+) TERMINAL INSULATOR (B+) TERMI- NAL FIELD TERMINALS
The battery temperature sensor i s l ocated under
vehi cl e battery (Fi g. 6) and i s attached to a mounti ng
hol e on battery tray.
REMOVAL
(1) Remove battery. Refer to Group 8A, Battery for
procedures.
(2) Di sconnect sensor pi gtai l harness from engi ne
wi re harness.
(3) Pry sensor strai ght up from battery tray
mounti ng hol e.
INSTALLATION
(1) Feed pi gtai l harness through hol e i n top of bat-
tery tray and press sensor i nto top of battery tray.
(2) Connect pi gtai l harness.
(3) I nstal l battery. Refer to Group 8A, Battery for
procedures.
SPECIFICATIONS
GENERATOR RATINGS
Description Torque
Generator Mounti ng Bol t
5.2L/5.9L Engi nes . . . . . . . . . . 41 Nm (30 ft. l bs.)
Generator Pi vot Bol t/Nut
.2L/5.9L Engi nes . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Generator Mounti ng Bol t
4.0L Engi ne . . . . . . . . . . . . . . 55 Nm (41 ft. l bs.)
Generator Pi vot Bol t/Nut
4.0L Engi ne . . . . . . . . . . . . . . 55 Nm (41 ft. l bs.)
Battery Termi nal Nut . . . . . . . . 8.5 Nm (75 i n. l bs.)
Ground Termi nal Nut . . . . . . . . 8.5 Nm (75 i n. l bs.)
Harness Hol d-down Nut . . . . . . 8.5 Nm (75 i n. l bs.)
Fi el d Termi nal Nuts . . . . . . . . . 2.8 Nm (25 i n. l bs.)
Fig. 6 Battery Temperature Sensor Location
ENGINE WIR- ING HARNESS BATTERY TEMPERATURE SENSOR SENSOR HARNESS BATTERYTRAY
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56005685 117 4.0L 90
DENSO 56005686 136 4.0L 120
DENSO 56027912 117 5.2L/5.9L 90
DENSO 56027913 136 5.2L/5.9L 120
CHARGING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
VACUUM PUMP TEST . . . . . . . . . . . . . . . . . . . . 1
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INTRODUCTION
The generator used on the 2.5L di esel engi ne i s
equi pped wi th a bui l t-on vacuum pump. Thi s pump,
i n conjuncti on wi th a second vacuum pump l ocated
wi thi n the engi ne, wi l l suppl y vacuum for: the heat/
A-C system, and power brake booster.
The generator/vacuum pump assembl y i s servi ced
as one part. I f the pump or generator shoul d be
faul ty, repl ace the enti re assembl y. The onl y servi ce-
abl e part i s the dri ve pul l ey.
VACUUM PUMP TEST
Refer to Group 5, Brake System for vacuum pump
i nformati on and testi ng.
GENERATOR
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.
(2) Remove generator/vacuum pump dri ve bel t.
Refer to Group 7, Cool i ng System for procedure.
(3) Remove the nut securi ng battery output cabl e
to B+ termi nal (Fi g. 1) at rear of generator.
(4) Unpl ug fi el d termi nal connector (Fi g. 1) at rear
of generator.
(5) Remove vacuum hose from upper vacuum hose
fi tti ng on vacuum pump (Fi g. 2).
(6) Remove upper generator mounti ng bol t.
(7) Loosen, but do not remove, the l ower generator
mounti ng bol t as requi red to gai n access to vacuum
pump oi l l i nes.
(8) Pl ace a drai n pan bel ow generator to catch oi l
from vacuum pump.
(9) Remove banjo bol t retai ni ng oi l feed hose (Fi g.
3) at bottom of vacuum pump.
(10) Loosen hose cl amp and remove oi l return hose
(Fi g. 2) from fi tti ng at bottom of pump.
(11) Remove l ower generator mounti ng bol t and
remove generator/vacuum pump from vehi cl e.
(12) Reverse the removal procedures for i nstal l a-
ti on. Ti ghten hardware i n order as fol l ows:
Banjo Bol t (Vacuum Pump Oi l Feed Hose)15
Nm (11 ft. l bs.)
Upper Generator Mounti ng Bol t27.5 Nm (20
ft. l bs.)
Lower Generator Mounti ng Bol t47 Nm (35 ft.
l bs.)
Battery Termi nal (generator B+ termi nal ) Nut
8.5 Nm (75 i n. l bs.)
SPECIFICATIONS
SPECIFICATIONS
Battery Terminal
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Nm
Lower Generator Mounting
Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm
Upper Generator Mounting
Bol t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 Nm
VacuumPump Oil Feed Hose
Banjo Bol t . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Fig. 1 Generator Terminals
Fig. 2 Generator/Vacuum Pump Remove/Install
Fig. 3 Vacuum Pump Oil Feed Hose
IGNITION SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 3
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 3
CRANKSHAFT POSITION SENSOR4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CRANKSHAFT POSITION SENSOR5.2L/5.9L
V-8 ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE COOLANT TEMPERATURE SENSOR . . 4
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 3
IGNITION SWITCH AND KEY LOCK CYLINDER . 4
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWERTRAIN CONTROL MODULE (PCM) . . . . 2
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . 3
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 2
THROTTLE POSITION SENSOR . . . . . . . . . . . . 4
AUTOMATIC SHUTDOWN (ASD) RELAY TEST . 4
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 7
CRANKSHAFT POSITION SENSOR . . . . . . . . . . 7
DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . . . 6
DISTRIBUTOR ROTOR . . . . . . . . . . . . . . . . . . . 6
ENGINE COOLANT TEMPERATURE SENSOR . . 8
FAILURE TO START TEST . . . . . . . . . . . . . . . . . 5
IGNITION COIL TEST . . . . . . . . . . . . . . . . . . . . . 5
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . 7
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPARK PLUG CONDITIONS . . . . . . . . . . . . . . . 9
TESTING FOR SPARK AT COIL . . . . . . . . . . . . . 4
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 14
CAMSHAFT POSITION SENSOR . . . . . . . . . . . 15
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DISTRIBUTOR4.0L ENGINE . . . . . . . . . . . . . 17
DISTRIBUTOR5.2L/5.9L ENGINES . . . . . . . . 16
ENGINE COOLANT TEMPERATURE SENSOR . 15
IGNITION COIL4.0L ENGINE . . . . . . . . . . . . . 13
IGNITION COIL5.2L/5.9L ENGINES . . . . . . . . 13
IGNITION SWITCH AND KEY CYLINDER . . . . . 20
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
POWERTRAIN CONTROL MODULE (PCM) . . . 20
SHIFTER/IGNITION INTERLOCK . . . . . . . . . . . 23
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 12
THROTTLE POSITION SENSOR . . . . . . . . . . . 15
SPECIFICATIONS
ENGINE FIRING ORDER4.0L 6-CYLINDER
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ENGINE FIRING ORDER5.2L/5.9L V-8
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
IGNITION COIL RESISTANCE . . . . . . . . . . . . . 24
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . 23
SPARK PLUG CABLE RESISTANCE . . . . . . . . 24
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 24
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 23
VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GENERAL INFORMATION
INTRODUCTION
Thi s group descri bes the i gni ti on systems for 5.2L/
5.9L V8 and 4.0L 6cyl i nder engi nes.
On Board Di agnosti cs i s descri bed i n Group 25,
Emi ssi on Control Systems.
Group 0, Lubri cati on and Mai ntenance, contai ns
general mai ntenance i nformati on (i n ti me or mi l eage
i nterval s) for i gni ti on rel ated i tems. The Owners
Manual al so contai ns mai ntenance i nformati on.
IGNITION SYSTEM
The i gni ti on systems used on 5.2L/5.9L V8 and
4.0L 6cyl i nder engi nes are basi cal l y i denti cal . Si mi -
l ari ti es and di fferences between the systems wi l l be
di scussed.
The i gni ti on system i s control l ed by the powertrai n
control modul e (PCM) on al l engi nes.
The i gni ti on system consi sts of:
Spark Pl ugs
ZG IGNITION SYSTEM 8D - 1
I gni ti on Coi l
Secondary I gni ti on Cabl es
Di stri butor (contai ns rotor and camshaft posi ti on
sensor)
Powertrai n Control Modul e (PCM)
Crankshaft Posi ti on, Camshaft Posi ti on, Throt-
tl e Posi ti on and MAP Sensors
POWERTRAIN CONTROL MODULE (PCM)
The Powertrai n Control Modul e (PCM) i s l ocated
i n the engi ne compartment (Fi g. 1).
The i gni ti on system i s control l ed by the PCM.
NOTE: Base ignition timing by rotation of distribu-
tor is not adjustable.
The PCM opens and cl oses the i gni ti on coi l ground
ci rcui t to operate the i gni ti on coi l . Thi s i s done to
adjust i gni ti on ti mi ng, both i ni ti al (base) and
advance, and for changi ng engi ne operati ng condi -
ti ons.
The amount of el ectroni c spark advance provi ded
by the PCM i s determi ned by fi ve i nput factors:
engi ne cool ant temperature, engi ne rpm, i ntake man-
i fol d temperature, mani fol d absol ute pressure and
throttl e posi ti on.
DISTRIBUTOR
Al l 4.0L/5.2L/5.9L engi nes are equi pped wi th a
camshaft dri ven mechani cal di stri butor contai ni ng a
shaft dri ven di stri butor rotor. Al l di stri butors are
equi pped wi th an i nternal camshaft posi ti on (fuel
sync) sensor (Fi g. 2). Thi s sensor provi des fuel i njec-
ti on synchroni zati on and cyl i nder i denti fi cati on.
The di stri butor does not have bui l t i n centri fugal
or vacuum assi sted advance. Base i gni ti on ti mi ng
and al l ti mi ng advance i s control l ed by the power-
trai n control modul e (PCM). Because i gni ti on ti mi ng
i s control l ed by the PCM, base ignition timing is
not adjustable on any of these engines.
On the 4.0L 6cyl i nder engi ne, the di stri butor i s
l ocked i n pl ace by a fork wi th a sl ot l ocated on the
di stri butor housi ng base. The di stri butor hol ddown
cl amp bol t passes through thi s sl ot when i nstal l ed.
Because the di stri butor posi ti on i s l ocked when
i nstal l ed, i ts rotati onal posi ti on can not be changed.
Do not attempt to modify the distributor hous-
ing to get distributor rotation. Distributor posi-
tion will have no effect on ignition timing. The
position of the distributor will determine fuel
synchronization only.
Al l 4.0L/5.2L/5.9L di stri butors contai n an i nternal
oi l seal that prevents oi l from enteri ng the di stri bu-
tor housi ng. The seal i s not servi ceabl e.
SPARK PLUGS
Al l engi nes use resi stor type spark pl ugs. Remove
the spark pl ugs and exami ne them for burned el ec-
trodes and foul ed, cracked or broken porcel ai n i nsu-
l ators. Keep pl ugs arranged i n the order i n whi ch
they were removed from the engi ne. A si ngl e pl ug
di spl ayi ng an abnormal condi ti on i ndi cates that a
probl em exi sts i n the correspondi ng cyl i nder. Repl ace
spark pl ugs at the i nterval s recommended i n Group
O, Lubri cati on and Mai ntenance
Spark pl ugs that have l ow mi l age may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Refer to the Spark Pl ug Condi ti on secti on of
thi s group.
Fig. 1 Powertrain Control Module (PCM) Location
PCM (3) 32-WAY CONNECTORS
Fig. 2 Distributor and CamshaftPosition Sensor-
Typical (5.2L/5.9L Shown)
SYNC SIGNAL GENERATOR CAMSHAFT POSITION SEN- SOR PULSE RING DISTRIBUTOR ASSEMBLY
8D - 2 IGNITION SYSTEM ZG
SPARK PLUG CABLES
Spark pl ug cabl es are someti mes referred to as sec-
ondary i gni ti on wi res. These cabl es transfer el ectri cal
current from the i gni ti on coi l (s) and/or di stri butor, to
i ndi vi dual spark pl ugs at each cyl i nder. The resi sti ve
spark pl ug cabl es are of nonmetal l i c constructi on.
The cabl es provi de suppressi on of radi o frequency
emi ssi ons from the i gni ti on system.
IGNITION COIL
Battery vol tage i s suppl i ed to the i gni ti on coi l pos-
i ti ve termi nal from the ASD rel ay.
The Powertrai n Control Modul e (PCM) opens and
cl oses the i gni ti on coi l ground ci rcui t for i gni ti on coi l
operati on.
Base ignition timing is not adjustable on any
engine. By control l i ng the coi l ground ci rcui t, the
PCM i s abl e to set the base ti mi ng and adjust the
i gni ti on ti mi ng advance. Thi s i s done to meet chang-
i ng engi ne operati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
AUTOMATIC SHUTDOWN (ASD) RELAY
As one of i ts functi ons, the ASD rel ay wi l l suppl y
battery vol tage to the i gni ti on coi l . The ground ci r-
cui t for the ASD rel ay i s control l ed by the Powertrai n
Control Modul e (PCM). The PCM regul ates ASD
rel ay operati on by swi tchi ng the ground ci rcui t
on-and-off.
CRANKSHAFT POSITION SENSOR5. 2L/5. 9L V-8
ENGINES
Engi ne speed and crankshaft posi ti on are provi ded
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the Pow-
ertrai n Control Modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
On 5.2L/5.9L V-8 engi nes, the fl ywheel /dri ve pl ate
has 8 si ngl e notches, spaced every 45 degrees, at i ts
outer edge (Fi g. 3).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on, there are 8
pul ses generated on V-8 engi nes.
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 SENSOR4. 0L ENGINE
Engi ne speed and crankshaft posi ti on are provi ded
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the pow-
ertrai n control modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
On 4.0L 6-cyl i nder engi nes, the fl ywheel /dri ve
pl ate has 3 sets of four notches at i ts outer edge (Fi g.
4).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on there are 3
sets of four pul ses generated.
The trai l i ng edge of the fourth notch, whi ch causes
the pul se, i s four degrees before top dead center
(TDC) of the correspondi ng pi ston.
CAMSHAFT POSITION SENSOR
The camshaft posi ti on sensor i s l ocated i n the di s-
tri butor on al l engi nes.
The sensor contai ns a hal l effect devi ce cal l ed a
sync si gnal generator to generate a fuel sync si gnal .
Thi s sync si gnal generator detects a rotati ng pul se
ri ng (shutter) on the di stri butor shaft. The pul se ri ng
Fig. 3 Sensor Operation5.2L/5.9LEngines
CRANKSHAFT POSITION SENSOR NOTCHES FLYWHEEL
rotates 180 degrees through the sync si gnal genera-
tor. I ts si gnal i s used i n conjuncti on wi th the crank-
shaft posi ti on sensor to di fferenti ate between fuel
i njecti on and spark events. I t i s al so used to synchro-
ni ze the fuel i njectors wi th thei r respecti ve cyl i nders.
When the l eadi ng edge of the pul se ri ng (shutter)
enters the sync si gnal generator, the fol l owi ng occurs:
The i nterrupti on of magneti c fi el d causes the vol tage
to swi tch hi gh resul ti ng i n a sync si gnal of approxi -
matel y 5 vol ts.
When the trai l i ng edge of the pul se ri ng (shutter)
l eaves the sync si gnal generator, the fol l owi ng occurs:
The change of the magneti c fi el d causes the sync si g-
nal vol tage to swi tch l ow to 0 vol ts.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
ENGINE COOLANT TEMPERATURE SENSOR
Fuel System.
THROTTLE POSITION SENSOR
Fuel System.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
Fuel System.
IGNITION SWITCH AND KEY LOCK CYLINDER
The i gni ti on swi tch i s l ocated on the steeri ng col -
umn. The Key-I n-Swi tch i s l ocated i n the i gni ti on
swi tch modul e. For el ectri cal di agnosi s of the Key-I n-
Swi tch, refer to Group 8U, Chi me/Buzzer Warni ng
Systems. For removal /i nstal l ati on of ei ther the key
l ock cyl i nder or i gni ti on swi tch, refer to I gni ti on
Swi tch and Key Cyl i nder Removal /I nstal l ati on i n thi s
group.
On vehi cl es equi pped wi th an automati c transmi s-
si on, a cabl e connects an i nterl ock devi ce wi thi n the
steeri ng col umn assembl y to the transmi ssi on fl oor
shi ft l ever. Thi s i nterl ock devi ce i s used to l ock the
transmi ssi on shi fter i n the PARK posi ti on when the
key i s i n the LOCKED or ACCESSORY posi ti on. The
i nterl ock devi ce i s not servi ceabl e. I f repai r i s neces-
sary, the steeri ng col umn assembl y must be repl aced.
Refer to Group 19, Steeri ng for procedures. The
shi fter i nterl ock cabl e can be adjusted or repl aced.
Refer to Group 21, Transmi ssi ons for procedures.
AUTOMATIC SHUTDOWN (ASD) RELAY TEST
To perform a compl ete test of thi s rel ay and i ts ci r-
cui try, refer to the DRB scan tool . Al so refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual . To test the rel ay onl y, refer to Rel aysOpera-
ti on/Testi ng i n the Group 14, Fuel Systems secti on.
TESTING FOR SPARK AT COIL
CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 5). Grasp the boot (not the cable) and
pull it off with a steady, even force.
(1) Di sconnect the i gni ti on coi l secondary cabl e
from center tower of the di stri butor cap. Hol d the
cabl e termi nal approxi matel y 12 mm (1/2 i n.) from a
good engi ne ground (Fi g. 6).
WARNING: BE VERY CAREFUL WHEN THE
ENGINE IS CRANKING. DO NOT PUT YOUR HANDS
NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT
WEAR LOOSE FITTING CLOTHING.
(2) Rotate (crank) the engi ne wi th the starter
motor and observe the cabl e termi nal for a steady
arc. I f steady arci ng does not occur, i nspect the sec-
Fig. 4 Sensor Operation4.0L 6-Cyl.Engine
CRANKSHAFT POSITION SENSOR FLYWHEEL FLYWHEEL NOTCHES
ondary coi l cabl e. Refer to Spark Pl ug Cabl es i n thi s
group. Al so i nspect the di stri butor cap and rotor for
cracks or burn marks. Repai r as necessary. I f steady
arci ng occurs, connect i gni ti on coi l cabl e to the di s-
tri butor cap.
(3) Remove a cabl e from one spark pl ug.
(4) Usi ng i nsul ated pl i ers, hol d the cabl e termi nal
approxi matel y 12 mm (1/2 i n.) from the engi ne cyl i n-
der head or bl ock whi l e rotati ng the engi ne wi th the
starter motor. Observe the spark pl ug cabl e termi nal
for an arc. I f steady arci ng occurs, i t can be expected
that the i gni ti on secondary system i s operati ng cor-
rectl y. (If the ignition coil cable is removed for
this test, instead of a spark plug cable, the
spark intensity will be much higher). I f steady
arci ng occurs at the spark pl ug cabl es, but the engi ne
wi l l not start, connect the DRB scan tool . Refer to
the appropri ate Powertrai n Di agnosti c Procedures
servi ce manual .
IGNITION COIL TEST
To perform a compl ete test of the i gni ti on coi l and
i ts ci rcui try, refer to the DRB scan tool . Al so refer to
the appropri ate Powertrai n Di agnosti cs Procedures
manual . To test the coi l onl y, refer to the fol l owi ng:
The i gni ti on coi l (Fi g. 7) i s desi gned to operate
wi thout an external bal l ast resi stor.
I nspect the i gni ti on coi l for arci ng. Test the coi l
accordi ng to coi l tester manufacturers i nstructi ons.
Test the coi l pri mary and secondary resi stance.
Repl ace any coi l that does not meet speci fi cati ons.
Refer to the I gni ti on Coi l Resi stance chart.
I f the i gni ti on coi l i s bei ng repl aced, the secondary
spark pl ug cabl e must al so be checked. Repl ace cabl e
i f i t has been burned or damaged.
Arci ng at the tower wi l l carboni ze the cabl e boot,
whi ch i f i t i s connected to a new i gni ti on coi l , wi l l
cause the coi l to fai l .
I f the secondary coi l cabl e shows any si gns of dam-
age, i t shoul d be repl aced wi th a new cabl e and new
termi nal . Carbon tracki ng on the ol d cabl e can cause
arci ng and the fai l ure of a new i gni ti on coi l .
FAILURE TO START TEST
To prevent unnecessary di agnosti c ti me and wrong
test resul ts, the Testi ng For Spark At Coi l test
shoul d be performed pri or to thi s test.
WARNING: SET PARKING BRAKE OR BLOCK THE
DRIVE WHEELS BEFORE PROCEEDING WITH THIS
TEST.
(1) Unpl ug the i gni ti on coi l harness connector at
the coi l .
(2) Connect a set of smal l jumper wi res (18 gauge
or smal l er) between the di sconnected harness termi -
nal s and the i gni ti on coi l termi nal s. To determi ne
pol ari ty at connector and coi l , refer to the Wi ri ng
Di agrams secti on.
Fig. 5 Cable Removal
SPARK PLUG CABLE AND BOOT SPARK PLUG BOOT PULLER TWIST AND PULL SPARK PLUG
Fig. 6 Checking for SparkTypical
A GOOD ENGINE GROUND CHECK HERE FOR SPARK IGNITION COIL
Fig. 7 Ignition CoilTypical (5.2L/5.9LShown)
COIL MOUNT- ING BOLTS ACCESSORY DRIVE BELT TENSIONER COIL CONNEC- TOR IGNITION COIL
(3) Attach one l ead of a vol tmeter to the posi ti ve
(12 vol t) jumper wi re. Attach the negati ve si de of
vol tmeter to a good ground. Determi ne that suffi ci ent
battery vol tage (12.4 vol ts) i s present for the starti ng
and i gni ti on systems.
(4) Determi ne that suffi ci ent battery vol tage (12.4
vol ts) i s present for the starti ng and i gni ti on sys-
tems.
(5) Crank the engi ne for 5 seconds whi l e moni tor-
i ng the vol tage at the coi l posi ti ve termi nal :
I f the vol tage remai ns near zero duri ng the
enti re peri od of cranki ng, refer to On-Board Di agnos-
ti cs i n Group 14, Fuel Systems. Check the Power-
trai n Control Modul e (PCM) and auto shutdown
rel ay.
I f vol tage i s at or near battery vol tage and drops
to zero after 1-2 seconds of cranki ng, check the pow-
ertrai n control modul e ci rcui t. Refer to On-Board
Di agnosti cs i n Group 14, Fuel Systems.
I f vol tage remai ns at or near battery vol tage
duri ng the enti re 5 seconds, turn the key off. Remove
the three 32-way connectors (Fi g. 8) from the PCM.
Check 32-way connectors for any spread termi nal s or
corrosi on.
(6) Remove test l ead from the coi l posi ti ve termi -
nal . Connect an 18 gauge jumper wi re between the
battery posi ti ve termi nal and the coi l posi ti ve termi -
nal .
(7) Make the speci al jumper shown i n (Fi g. 9).
Usi ng the jumper, momentarily ground the i gni ti on
coi l dri ver ci rcui t at the PCM connector (cavi ty A-7).
For cavi ty/termi nal l ocati on of thi s ci rcui t, refer to
Group 8W, Wi ri ng. A spark shoul d be generated at
the coi l cabl e when the ground i s removed.
(8) I f spark i s generated, repl ace the PCM.
(9) I f spark i s not seen, use the speci al jumper to
ground the coi l negati ve termi nal di rectl y.
(10) I f spark i s produced, repai r wi ri ng harness for
an open condi ti on.
(11) I f spark i s not produced, repl ace the i gni ti on
coi l .
DISTRIBUTOR CAP
Remove the di stri butor cap and wi pe i t cl ean wi th
a dry l i nt free cl oth. Vi sual l y i nspect the cap for
cracks, carbon paths, broken towers or damaged
rotor button (Fi g. 10) or (Fi g. 11). Al so check for
whi te deposi ts on the i nsi de (caused by condensati on
enteri ng the cap through cracks). Repl ace any cap
that di spl ays charred or eroded termi nal s. The
machi ned surface of a termi nal end (faces toward
rotor) wi l l i ndi cate some evi dence of erosi on from
normal operati on. Exami ne the termi nal ends for evi -
dence of mechani cal i nterference wi th the rotor ti p.
DISTRIBUTOR ROTOR
Vi sual l y i nspect the rotor (Fi g. 12) for cracks, evi -
dence of corrosi on or the effects of arci ng on the
metal ti p. Al so check for evi dence of mechani cal
i nterference wi th the cap. Some charri ng i s normal
COIL (MANUFACTURER)
PRIMARY RESISTANCE
21-27C (70-80F)
SECONDARY RESISTANCE
21-27C (70-80F)
Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms
Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms
IGNITION COIL RESISTANCE
Fig. 8 PCM and Three 32Way Connectors
PCM (3) 32WAY CONNECTORS
Fig. 9 Special Jumper Ground-to-Coil
NegativeTerminal
CAPACITOR CONNECT THIS CLIP TO COIL NEG- ATIVE ALLIGATOR CLIP MOMENTARILY GROUND THIS CLIP TO COIL NEGATIVE .33 MF ALLIGATOR CLIP GROUND THIS CLIP
on the end of the metal ti p. The si l i cone-di el ectri c-
varni sh-compound appl i ed to the rotor ti p for radi o
i nterference noi se suppressi on, wi l l appear charred.
Thi s i s normal . Do not remove the charred com-
pound. Test the spri ng for i nsuffi ci ent tensi on.
Repl ace a rotor that di spl ays any of these adverse
condi ti ons.
IGNITION TIMING
NOTE: Base (initial) ignition timing is NOT adjust-
able on any 4.0L/5.2L/5.9L engine. Do not attempt to
adjust ignition timing by rotating the distributor.
NOTE: On 4.0L 6cylinder engines, do not attempt
to modify the slotted fork on the distributor housing
to get distributor rotation. Distributor position will
have no effect on ignition timing.
Al l i gni ti on ti mi ng functi ons are control l ed by the
powertrai n control modul e (PCM). For addi ti onal
i nformati on, refer to the appropri ate Powertrai n
Di agnosti cs Procedures servi ce manual for operati on
of the DRB Scan Tool .
MAP SENSOR
For an operati onal descri pti on, di agnosi s or remov-
al / i nstal l ati on procedures, refer to Group 14, Fuel
Systems.
CRANKSHAFT POSITION SENSOR
ci rcui try, refer to the DRB scan tool . Al so refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual .
tri butor (Fi g. 13) on al l engi nes.
ci rcui try, refer to the appropri ate Powertrai n Di ag-
nosti cs Procedures servi ce manual . To test the sensor
onl y, refer to the fol l owi ng:
For this test, an analog (non-digital) voltme-
ter is needed. Do not remove the di stri butor connec-
tor from the di stri butor. Usi ng smal l paper cl i ps,
i nsert them i nto the backsi de of the di stri butor wi re
harness connector to make contact wi th the termi -
nal s. Be sure that the connector i s not damaged
when i nserti ng the paper cl i ps. Attach vol tmeter
l eads to these paper cl i ps.
(1) Connect the posi ti ve (+) vol tmeter l ead i nto the
sensor output wi re. Thi s i s at done the di stri butor
wi re harness connector. For wi re i denti fi cati on, refer
to Group 8W, Wi ri ng Di agrams.
Fig. 10 Cap InspectionExternalTypical
BROKEN TOWER DISTRIBUTOR CAP CARBON PATH CRACK
Fig. 11 Cap InspectionInternalTypical
CHARRED OR ERODED TER- MINALS WORN OR DAM- AGED ROTOR BUT- TON CARBONPATH
Fig. 12 Rotor InspectionTypical
INSUFFICIENT SPRING TEN- SION CRACKS EVIDENCE OF PHYSICAL CONTACT WITH CAP ROTOR TIP CORRODED
(2) Connect the negati ve (-) vol tmeter l ead i nto the
ground wi re. For wi re i denti fi cati on, refer to Group
8W, Wi ri ng Di agrams.
(3) Set the vol tmeter to the 15 Vol t DC scal e.
(4) 5.2L/5.9L Engines: Remove di stri butor cap
from di stri butor (two screws). Rotate (crank) the
engi ne unti l the di stri butor rotor i s poi nted towards
the rear of vehi cl e. The movabl e pul se ri ng shoul d
now be wi thi n the sensor pi ckup.
(5) 4.0L Engine: Remove di stri butor cap from
di stri butor (two screws). Rotate (crank) the engi ne
unti l the di stri butor rotor i s poi nted to approxi matel y
the 11 ocl ock posi ti on. The movabl e pul se ri ng
shoul d now be wi thi n the sensor pi ckup.
(6) Turn i gni ti on key to ON posi ti on. Vol tmeter
shoul d read approxi matel y 5.0 vol ts.
(7) I f vol tage i s not present, check the vol tmeter
l eads for a good connecti on.
(8) I f vol tage i s sti l l not present, check for vol tage
at the suppl y wi re. For wi re i denti fi cati on, refer to
Group 8W, Wi ri ng Di agrams.
(9) I f 5 vol ts i s not present at suppl y wi re, check
for vol tage at PCM 32-way connector (cavi ty A-17).
Refer to Group 8W, Wi ri ng for l ocati on of connector/
termi nal . Leave the PCM connector connected for
thi s test.
(10) I f vol tage i s sti l l not present, perform vehi cl e
test usi ng the DRB scan tool .
(11) I f vol tage i s present at cavi ty A-17, but not at
the suppl y wi re:
(a) Check conti nui ty between the suppl y wi re.
Thi s i s checked between the di stri butor connector
and cavi ty A-17 at the PCM. I f conti nui ty i s not
present, repai r the harness as necessary.
(b) Check for conti nui ty between the camshaft
posi ti on sensor output wi re and cavi ty A-18 at the
PCM. I f conti nui ty i s not present, repai r the har-
ness as necessary.
(c) Check for conti nui ty between the ground ci r-
cui t wi re at the di stri butor connector and ground.
I f conti nui ty i s not present, repai r the harness as
necessary.
(12) Whi l e observi ng the vol tmeter, crank the
engi ne wi th i gni ti on swi tch. The vol tmeter needl e
shoul d fl uctuate between 0 and 5 vol ts whi l e the
engi ne i s cranki ng. Thi s veri fi es that the camshaft
posi ti on sensor i n the di stri butor i s operati ng prop-
erl y and a sync pul se si gnal i s bei ng generated.
I f sync pul se si gnal i s not present, repl acement of
the camshaft posi ti on sensor i s necessary
Fuel System.
Fuel System.
SPARK PLUG CABLES
Check the spark pl ug cabl e connecti ons for good
contact at the coi l (s), di stri butor cap towers, and
spark pl ugs. Termi nal s shoul d be ful l y seated. The
i nsul ators shoul d be i n good condi ti on and shoul d fi t
ti ghtl y on the coi l , di stri butor and spark pl ugs. Spark
pl ug cabl es wi th i nsul ators that are cracked or torn
must be repl aced.
Cl ean hi gh vol tage i gni ti on cabl es wi th a cl oth
moi stened wi th a non-fl ammabl e sol vent. Wi pe the
cabl es dry. Check for bri ttl e or cracked i nsul ati on.
On 5.2L/5.9L V-8 engi nes, spark pl ug cabl e heat
shi el ds are pressed i nto the cyl i nder head to sur-
round each spark pl ug cabl e boot and spark pl ug
(Fi g. 14). These shi el ds protect the spark pl ug boots
from damage (due to i ntense engi ne heat generated
by the exhaust mani fol ds) and shoul d not be
removed. After the spark pl ug cabl e has been
i nstal l ed, the l i p of the cabl e boot shoul d have a
smal l ai r gap to the top of the heat shi el d (Fi g. 14).
TESTING
When testi ng secondary cabl es for damage wi th an
osci l l oscope, fol l ow the i nstructi ons of the equi pment
manufacturer.
I f an osci l l oscope i s not avai l abl e, spark pl ug cabl es
may be tested as fol l ows:
Fig. 13 Camshaft Position SensorTypical(5.2L/5.9L
Distributor Shown)
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Wi th the engi ne runni ng, remove spark pl ug cabl e
from spark pl ug (one at a ti me) and hol d next to a
good engi ne ground. I f the cabl e and spark pl ug are
i n good condi ti on, the engi ne rpm shoul d drop and
the engi ne wi l l run poorl y. I f engi ne rpm does not
drop, the cabl e and/or spark pl ug may not be operat-
i ng properl y and shoul d be repl aced. Al so check
engi ne cyl i nder compressi on.
Wi th the engi ne not runni ng, connect one end of a
test probe to a good ground. Start the engi ne and run
the other end of the test probe al ong the enti re
l ength of al l spark pl ug cabl es. I f cabl es are cracked
or punctured, there wi l l be a noti ceabl e spark jump
from the damaged area to the test probe. The cabl e
runni ng from the i gni ti on coi l to the di stri butor cap
can be checked i n the same manner. Cracked, dam-
aged or faul ty cabl es shoul d be repl aced wi th resi s-
tance type cabl e. Thi s can be i denti fi ed by the words
ELECTRONI C SUPPRESSI ON pri nted on the cabl e
jacket.
Use an ohmmeter to test for open ci rcui ts, exces-
si ve resi stance or l oose termi nal s. I f equi pped,
remove the di stri butor cap from the di stri butor. Do
not remove cables from cap. Remove cabl e from
spark pl ug. Connect ohmmeter to spark pl ug termi -
nal end of cabl e and to correspondi ng el ectrode i n
di stri butor cap. Resi stance shoul d be 250 to 1000
Ohms per i nch of cabl e. I f not, remove cabl e from di s-
tri butor cap tower and connect ohmmeter to the ter-
mi nal ends of cabl e. I f resi stance i s not wi thi n
speci fi cati ons as found i n the Spark Pl ug Cabl e
Resi stance chart, repl ace the cabl e. Test al l spark
pl ug cabl es i n thi s manner.
To test i gni ti on coi l -to-di stri butor cap cabl e, do not
remove the cabl e from the cap. Connect ohmmeter to
rotor button (center contact) of di stri butor cap and
termi nal at i gni ti on coi l end of cabl e. I f resi stance i s
not wi thi n speci fi cati ons as found i n the Spark Pl ug
Cabl e Resi stance chart, remove the cabl e from the
di stri butor cap. Connect the ohmmeter to the termi -
nal ends of the cabl e. I f resi stance i s not wi thi n spec-
i fi cati ons as found i n the Spark Pl ug Cabl e
Resi stance chart, repl ace the cabl e. I nspect the i gni -
ti on coi l tower for cracks, burns or corrosi on.
SPARK PLUG CONDITIONS
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
(Fi g. 15). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than
approxi matel y 0.025 mm (.001 i n) per 1600 km (1000
mi l es) of operati on. Spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes
fi l ed, have the gap set and then be i nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance i s not
affected by MMT deposi ts.
Fig. 14 Heat Shields5.2L/5.9LV-8 Engines
AIR GAP SPARK PLUG BOOT HEAT SHIELD
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
SPARK PLUG CABLE RESISTANCE
Fig. 15 Normal Operation and Cold (Carbon)Fouling
NORMAL DRY BLACK DEPOSITS COLD (CARBON) FOULING
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 15). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 16), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 17).
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 18). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
Fig. 16 Oil or Ash Encrusted
Fig. 17 Electrode Gap Bridging
GROUND ELECTRODE DEPOSITS CENTER ELECTRODE
MINIMUM MAXIMUM
Fig. 18 Scavenger Deposits
GROUND ELECTRODE COV- ERED WITH WHITE OR YEL- LOW DEPOSITS CENTER ELEC- TRODE
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 19). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PREIGNITION DAMAGE
Prei gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 20). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
21). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 1000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
SPARK PLUG CABLES
CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 22). Grasp the boot (not the cable) and
pull it off with a steady, even force.
I nstal l cabl es i nto the proper engi ne cyl i nder fi ri ng
order (Fi g. 23) or (Fi g. 24).
When repl aci ng the spark pl ug and coi l cabl es,
route the cabl es correctl y and secure i n the proper
retai ners. Fai l ure to route the cabl es properl y can
cause the radi o to reproduce i gni ti on noi se. I t coul d
al so cause cross i gni ti on of the pl ugs or short ci rcui t
the cabl es to ground.
When i nstal l i ng new cabl es, make sure a posi ti ve
connecti on i s made. A snap shoul d be fel t when a
good connecti on i s made between the pl ug cabl e and
the di stri butor cap tower.
Fig. 19 Chipped Electrode Insulator
GROUND ELECTRODE CENTER ELECTRODE CHIPPED INSULATOR
Fig. 20 Preignition Damage
GROUND ELECTRODE STARTING TO DISSOLVE CENTER ELECTRODE DISSOLVED
Fig. 21 Spark PlugOverheating
BLISTERED WHITE OR GRAY COLORED INSULATOR
SPARK PLUGS
On 5.2L/5.9L V-8 engi nes, spark pl ug cabl e heat
shi el ds are pressed i nto the cyl i nder head to sur-
round each cabl e boot and spark pl ug (Fi g. 25).
I f removal of the heat shi el d(s) i s necessary,
remove the spark pl ug cabl e and compress the si des
of shi el d for removal . Each shi el d i s sl otted to al l ow
for compressi on and removal . To i nstal l the shi el ds,
al i gn shi el d to machi ned openi ng i n cyl i nder head
and tap i nto pl ace wi th a bl ock of wood.
PLUG REMOVAL
(1) Al ways remove spark pl ug or i gni ti on coi l
cabl es by graspi ng at the cabl e boot (Fi g. 22). Turn
the cabl e boot 1/2 turn and pul l strai ght back i n a
steady moti on. Never pul l di rectl y on the cabl e.
I nternal damage to cabl e wi l l resul t.
(2) Pri or to removi ng the spark pl ug, spray com-
pressed ai r around the spark pl ug hol e and the area
around the spark pl ug. Thi s wi l l hel p prevent forei gn
materi al from enteri ng the combusti on chamber.
(3) Remove the spark pl ug usi ng a qual i ty socket
wi th a rubber or foam i nsert.
(4) I nspect the spark pl ug condi ti on. Refer to
Spark Pl ug Condi ti on i n the Di agnosti cs and Testi ng
secti on of thi s group.
PLUG CLEANING
The pl ugs may be cl eaned usi ng commerci al l y
avai l abl e spark pl ug cl eani ng equi pment. After cl ean-
i ng, fi l e the center el ectrode fl at wi th a smal l poi nt
fi l e or jewel ers fi l e before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
Fig. 22 Cable Removal
SPARK PLUG CABLE AND BOOT SPARK PLUG BOOT PULLER TWIST AND PULL SPARK PLUG
Fig. 23 Engine Firing Order4.0L 6Cyl.Engine
FIRING ORDER: 1 5 3 6 2 4 CLOCKWISE ROTATION FRONT
Fig. 24 Engine Firing Order5.2L/5.9LV-8 Engines
FRONT OFENGINE CLOCKWISE ROTATION 1-8-4-3-6-5-7-2
Fig. 25 Heat Shields5.2L/5.9LEngines
AIR GAP SPARK PLUG BOOT HEAT SHIELD
PLUG GAP ADJ USTMENT
Check the spark pl ug gap wi th a gap gauge tool . I f
the gap i s not correct, adjust i t by bendi ng the
ground el ectrode (Fi g. 26). Never attempt to adjust
the gap by bending the center electrode.
SPARK PLUG GAP
4.0L 6Cyl. Engine: .89 mm (.035 i n).
5.2L V-8 Engines: 1.01 mm (.040 i n).
5.9L V-8 Engines: .89 mm (.035 i n).
PLUG INSTALLATION
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
When repl aci ng the spark pl ug and i gni ti on coi l
cabl es, route the cabl es correctl y and secure them i n
the appropri ate retai ners. Fai l ure to route the cabl es
properl y can cause the radi o to reproduce i gni ti on
noi se. I t coul d cause cross i gni ti on of the spark pl ugs
or short ci rcui t the cabl es to ground.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Ti ghten spark pl ugs to 35-41 Nm (26-30 ft.
l bs.) torque.
(3) I nstal l spark pl ug cabl es over spark pl ugs.
IGNITION COIL5. 2L/5. 9L ENGINES
The i gni ti on coi l i s an epoxy fi l l ed type. I f the coi l
i s repl aced, i t must be repl aced wi th the same type.
REMOVAL
The coi l i s mounted to a bracket that i s bol ted to
the front of the ri ght engi ne cyl i nder head (Fi g. 27).
Thi s bracket i s mounted on top of the automati c bel t
tensi oner bracket usi ng common bol ts.
(1) Di sconnect the pri mary wi ri ng from the i gni -
ti on coi l .
(2) Di sconnect the secondary spark pl ug cabl e from
the i gni ti on coi l .
WARNING: DO NOT REMOVE THE COIL MOUNT-
ING BRACKET-TO-CYLINDER HEAD MOUNTING
BOLTS. THE COIL MOUNTING BRACKET IS UNDER
ACCESSORY DRIVE BELT TENSION. IF THIS
BRACKET IS TO BE REMOVED FOR ANY REASON,
ALL BELT TENSION MUST FIRST BE RELIEVED.
REFER TO THE BELT SECTION OF GROUP 7,
COOLING SYSTEM.
(3) Remove i gni ti on coi l from coi l mounti ng
bracket (two bol ts).
INSTALLATION
(1) I nstal l the i gni ti on coi l to coi l bracket. I f nuts
and bol ts are used to secure coi l to coi l bracket,
ti ghten to 11 Nm (100 i n. l bs.) torque. I f the coi l
mounti ng bracket has been tapped for coi l mounti ng
bol ts, ti ghten bol ts to 5 Nm (50 i n. l bs.) torque.
(2) Connect al l wi ri ng to i gni ti on coi l .
IGNITION COIL4. 0L ENGINE
The i gni ti on coi l i s an epoxy fi l l ed type. I f the coi l
i s repl aced, i t must be repl aced wi th the same type.
Fig. 26 Setting Spark Plug GapTypical
GAUGE SPARK PLUG
Fig. 27 Ignition Coil5.2L/5.9L V-8Engines
REMOVAL
The i gni ti on coi l i s mounted to a bracket on the
si de of the engi ne to the front of the di stri butor (Fi g.
28).
(1) Di sconnect the i gni ti on coi l secondary cabl e
from i gni ti on coi l (Fi g. 28).
(2) Di sconnect engi ne harness connector from i gni -
ti on coi l .
(3) Remove i gni ti on coi l mounti ng bol ts (nuts may
al so be used on back si de of bracket).
(4) Remove coi l .
INSTALLATION
(1) I nstal l i gni ti on coi l to bracket. I f nut and bol ts
are used to secure coi l to coi l bracket, ti ghten to 11
Nm (100 i n. l bs.) torque. I f bol ts are used, ti ghten
bol ts to 5 Nm (50 i n. l bs.) torque.
(2) Connect engi ne harness connector to coi l .
(3) Connect i gni ti on coi l cabl e to i gni ti on coi l .
The Automati c Shutdown (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. 29). Refer to
l abel on PDC cover for rel ay l ocati on. Check the ter-
mi nal s i n the PDC rel ay connector for corrosi on or
damage before i nstal l ati on.
CRANKSHAFT POSITION SENSOR5. 2L/5. 9L
ENGINES
REMOVAL
The sensor i s bol ted to the top of the cyl i nder bl ock
near the rear of ri ght cyl i nder head (Fi g. 30).
(1) Di sconnect crankshaft posi ti on sensor pi gtai l
harness (3way connector) from mai n wi ri ng harness.
(2) Remove two sensor (recessed hex head) mount-
i ng bol ts (Fi g. 30).
(3) Remove sensor from engi ne.
INSTALLATION
(1) Posi ti on crankshaft posi ti on sensor to engi ne.
(2) I nstal l mounti ng bol ts and ti ghten to 8 Nm (70
i n. l bs.) torque.
(3) Connect mai n harness el ectri cal connector to
sensor.
CRANKSHAFT POSITION SENSOR4. 0L ENGINE
The crankshaft posi ti on sensor i s mounted to the
transmi ssi on bel l housi ng at the l eft/rear si de of the
engi ne bl ock (Fi g. 31). The sensor i s attached wi th
Fig. 28 Ignition Coil4.0L Engine
ELECTRICAL CONNECTOR
IGNITION COIL
MOUNTING BOLTS (2)
Fig. 30 Crankshaft Position Sensor5.2L/
5.9LEngines
GROMMET
MOUNTING BOLTS (2)
one bol t. A wi re shi el d/router i s attached to the sen-
sor (Fi g. 31).
REMOVAL
(1) Di sconnect sensor pi gtai l harness (3way con-
nector) from mai n engi ne wi ri ng harness. Thi s con-
necti on i s made near rear of di stri butor.
(2) Remove sensor mounti ng bol t.
(3) Remove wi re shi el d and sensor.
INSTALLATION
(1) Posi ti on sensor fl ush agai nst machi ned area
and i nto openi ng on transmi ssi on bel l housi ng.
(2) Posi ti on sensor wi re shi el d to sensor (Fi g. 31).
(3) I nstal l bol t through wi re shi el d and sensor.
(4) Ti ghten sensor mounti ng bol t to 7 Nm (60 i n.
l bs.) torque.
(5) Route wi ri ng harness i nto wi re shi el d.
(6) Connect 3way sensor el ectri cal connectors.
tri butor on al l 4.0L 6cyl i nder and 5.2L/5.9L V-8
engi nes (Fi g. 32).
REMOVAL
Di stri butor removal i s not necessary to remove
camshaft posi ti on sensor.
(1) 5.2L/5.9L Engi nes: Remove ai r cl eaner tube at
throttl e body.
(2) Di sconnect negati ve cabl e from battery.
(3) Remove di stri butor cap from di stri butor (two
screws).
(4) Di sconnect camshaft posi ti on sensor wi ri ng
harness from mai n engi ne wi ri ng harness.
(5) Remove di stri butor rotor from di stri butor shaft.
(6) Li ft the camshaft posi ti on sensor assembl y
from the di stri butor housi ng (Fi g. 32).
INSTALLATION
(1) I nstal l camshaft posi ti on sensor to di stri butor.
Al i gn sensor i nto notch on di stri butor housi ng.
(2) Connect wi ri ng harness.
(3) I nstal l rotor.
(4) I nstal l di stri butor cap. Ti ghten mounti ng
screws.
(5) 5.2L/5.9L Engi nes: I nstal l ai r cl eaner tube to
throttl e body.
For removal and i nstal l ati on, refer to Mani fol d
Absol ute Pressure Sensor i n group 14, Fuel Systems.
Fuel System.
Fuel System.
Fuel System.
Fig. 31 Crankshaft Position Sensor4.0L6-Cylinder
Engine
PIGTAIL HARNESS TO DIS- TRIBUTOR SIDE OF ENGINE
Fig. 32 Camshaft Position SensorTypical
(5.2L/5.9L Shown)
DISTRIBUTOR5. 2L/5. 9L ENGINES
REMOVAL
CAUTION: Base ignition timing is not adjustable
on any 5.2L/5.9L V-8 engine. Distributors do not
have built in centrifugal or vacuum assisted
advance. Base ignition timing and timing advance
are controlled by the Powertrain Control Module
(PCM). Because a conventional timing light can not
be used to adjust distributor position after installa-
tion, note position of distributor before removal.
(2) Remove ai r cl eaner tube at throttl e body.
(3) Di sconnect coi l secondary cabl e at di stri butor
cap.
(4) Di sconnect al l secondary spark pl ug cabl es at
di stri butor cap. Note and mark posi ti on before
removal .
(5) Remove di stri butor cap from di stri butor (two
screws).
(6) Mark the posi ti on of di stri butor housi ng i n
rel ati onshi p to engi ne or dash panel . Thi s i s done to
ai d i n i nstal l ati on.
(7) Before di stri butor i s removed, the number one
cyl i nder must be brought to the Top Dead Center
(TDC) fi ri ng posi ti on.
(8) Attach a socket to the Crankshaft Vi brati on
Damper mounti ng bol t.
(9) Sl owl y rotate engi ne cl ockwi se, as vi ewed from
front, unti l i ndi cati ng mark on crankshaft vi brati on
damper i s al i gned to 0 degree (TDC) mark on ti mi ng
chai n cover (Fi g. 33).
(10) The di stri butor rotor shoul d now be al i gned to
the CYL. NO. 1 al i gnment mark (stamped) i nto the
camshaft posi ti on sensor (Fi g. 34). I f not, rotate the
crankshaft through another compl ete 360 degree
turn. Note the posi ti on of the number one cyl i nder
spark pl ug cabl e (on the cap) i n rel ati on to rotor.
Rotor shoul d now be al i gned to thi s posi ti on.
(11) Di sconnect camshaft posi ti on sensor wi ri ng
harness 3way connector from mai n engi ne wi ri ng
harness.
(12) Remove di stri butor rotor from di stri butor
shaft.
(13) Remove di stri butor hol ddown cl amp bol t and
cl amp (Fi g. 35).
(14) Remove di stri butor from vehi cl e.
CAUTION: Do not crank engine with distributor
removed. Distributor/crankshaft relationship will be
lost.
INSTALLATION
I f engi ne has been cranked whi l e di stri butor i s
removed, establ i sh the rel ati onshi p between di stri bu-
tor shaft and number one pi ston posi ti on as fol l ows:
Fig. 33 Damper-To-Cover Alignment MarksTypical
ALIGNMENT MARK TIMING CHAIN COVERMARKS CRANKSHAFT VIBRATIONDAMPER
Fig. 34 Rotor Alignment Mark5.2L/5.9LEngines
CAMSHAFT POSITION SENSOR ALIGNMENT MARK ROTOR DISTRIBUTOR
Fig. 35 Distributor Holddown Clamp5.2L/
5.9LEngines
CLAMP BOLT HOLDDOWN CLAMP DISTRIBUTOR HOUSING
Rotate crankshaft i n a cl ockwi se di recti on, as
vi ewed from front, unti l number one cyl i nder pi ston
i s at top of compressi on stroke (compressi on shoul d
be fel t on fi nger wi th number one spark pl ug
removed). Then conti nue to sl owl y rotate engi ne
cl ockwi se unti l i ndi cati ng mark (Fi g. 33) i s al i gned to
0 degree (TDC) mark on ti mi ng chai n cover.
(1) Cl ean top of cyl i nder bl ock for a good seal
between di stri butor base and bl ock.
(2) Li ghtl y oi l the rubber o-ri ng seal on the di stri b-
utor housi ng.
(3) I nstal l rotor to di stri butor shaft.
(4) Posi ti on di stri butor i nto engi ne to i ts ori gi nal
posi ti on. Engage tongue of di stri butor shaft wi th sl ot
i n di stri butor oi l pump dri ve gear. Posi ti on rotor to
the number one spark pl ug cabl e posi ti on.
(5) I nstal l di stri butor hol ddown cl amp and cl amp
bol t. Do not ti ghten bol t at thi s ti me.
(6) Rotate the di stri butor housi ng unti l rotor i s
al i gned to CYL. NO. 1 al i gnment mark on the cam-
shaft posi ti on sensor (Fi g. 34).
(7) Ti ghten cl amp hol ddown bol t (Fi g. 35) to 22.5
(8) Connect camshaft posi ti on sensor wi ri ng har-
ness to mai n engi ne harness.
(9) I nstal l di stri butor cap. Ti ghten mounti ng
screws.
(10) I nstal l secondary cabl es to di stri butor cap.
(11) Refer to the fol l owi ng, Checki ng Di stri butor
Posi ti on.
CHECKING DISTRIBUTOR POSITION
To veri fy correct di stri butor rotati onal posi ti on,
connect the DRB scan tool to the data l i nk connector.
The data l i nk connector i s l ocated i n the passenger
compartment, bel ow and to the l eft of steeri ng col -
umn. Gai n access to the SET SYNC screen on the
DRB.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
Fol l ow the di recti ons on the DRB screen and start
the engi ne. Wi th the engi ne runni ng, the words I N
RANGE shoul d appear on the screen al ong wi th 0.
Thi s i ndi cates correct di stri butor posi ti on.
I f a pl us (+) or a mi nus (-) i s di spl ayed next to the
degree number, and/or the degree di spl ayed i s not
zero, l oosen but do not remove the di stri butor hol d-
down cl amp bol t. Rotate the di stri butor unti l I N
RANGE appears on the screen. Conti nue to rotate
the di stri butor unti l achi evi ng as cl ose to 0 as pos-
si bl e. After adjustment, ti ghten cl amp bol t to 22.5
The degree scal e on the SET SYNC screen of the
DRB i s referri ng to fuel synchroni zati on onl y. It is
not referring to ignition timing. Because of thi s,
do not attempt to adjust i gni ti on ti mi ng usi ng thi s
method. Rotati ng the di stri butor wi l l have no effect
on i gni ti on ti mi ng. Al l i gni ti on ti mi ng val ues are con-
trol l ed by the powertrai n control modul e (PCM).
After testi ng, i nstal l ai r cl eaner tube to throttl e
body.
DISTRIBUTOR4. 0L ENGINE
Al l 4.0L di stri butors contai n an i nternal oi l seal
that prevents oi l from enteri ng the di stri butor hous-
i ng. The seal i s not servi ceabl e.
Factory repl acement di stri butors are equi pped wi th
a pl asti c al i gnment pi n al ready i nstal l ed. The pi n i s
l ocated i n an access hol e on the bottom of the di stri b-
utor housi ng (Fi g. 36). I t i s used to temporari l y l ock
the rotor to the cyl i nder number 1 posi ti on duri ng
i nstal l ati on. The pi n must be removed after i nstal l -
i ng the di stri butor.
tri butor on al l 4.0L engi nes (Fi g. 37). For removal /i n-
stal l ati on procedures, refer to Camshaft Posi ti on
Sensor. Di stri butor removal i s not necessary for sen-
sor removal .
Refer to (Fi g. 37) for an expl oded vi ew of di stri bu-
tor.
A fork wi th a sl ot i s suppl i ed on bottom of di stri b-
utor housi ng where the housi ng base seats agai nst
engi ne bl ock (Fi g. 37). The centerl i ne of the sl ot
al i gns wi th di stri butor hol ddown bol t hol e i n engi ne
bl ock. Because of the fork, the di stri butor cannot be
Fig. 36 Plastic Alignment Pin4.0LEngine
PLASTIC ALIGN- MENT PIN
rotated. Di stri butor rotati on i s not necessary as al l
i gni ti on ti mi ng requi rements are handl ed by the
powertrai n control modul e (PCM).
The posi ti on of di stri butor determi nes fuel synchro-
ni zati on onl y. I t does not determi ne i gni ti on ti mi ng.
NOTE: Do not attempt to modify this fork to attain
ignition timing.
REMOVAL4.0L ENGINE
(2) Di sconnect coi l secondary cabl e at coi l .
(3) Remove di stri butor cap from di stri butor (2
screws). Do not remove cabl es from cap. Do not
remove rotor.
(4) Di sconnect di stri butor wi ri ng harness 3way
connector from mai n engi ne harness.
(5) Remove cyl i nder number 1 spark pl ug.
(6) Hol d a fi nger over the open spark pl ug hol e.
Rotate engi ne at vi brati on dampener bol t unti l com-
pressi on (pressure) i s fel t.
(7) Sl owl y conti nue to rotate engi ne. Do thi s unti l
ti mi ng i ndex mark on vi brati on damper pul l ey al i gns
wi th top dead center (TDC) mark (0 degree) on ti m-
i ng degree scal e (Fi g. 38). Al ways rotate engi ne i n
di recti on of normal rotati on. Do not rotate engi ne
backward to al i gn ti mi ng marks.
(8) Remove di stri butor hol ddown bol t and cl amp.
(9) Remove di stri butor from engi ne by sl owl y l i ft-
i ng strai ght up.
(10) Note that rotor wi l l rotate sl i ghtl y i n a coun-
tercl ockwi se di recti on whi l e l i fti ng up the di stri butor.
The oi l pump gear wi l l al so rotate sl i ghtl y i n a coun-
tercl ockwi se di recti on whi l e l i fti ng up the di stri butor.
Thi s i s due to the hel i cal cut gears on di stri butor and
camshaft.
(11) Note removed posi ti on of rotor duri ng di stri b-
utor removal . Duri ng i nstal l ati on, thi s wi l l be
referred to as the Pre-posi ti on.
(12) Observe sl ot i n oi l pump gear through hol e on
si de of engi ne. I t shoul d be sl i ghtl y before (counter-
cl ockwi se of) the 11 ocl ock posi ti on (Fi g. 39).
(13) Remove and di scard ol d di stri butor-to-engi ne
bl ock gasket.
INSTALLATION
(1) I f engi ne crankshaft has been rotated after di s-
tri butor removal , cyl i nder number 1 must be
returned to i ts proper fi ri ng stroke. Refer to previ ous
REMOVAL Step 5 and Step 6. These steps must be
done before i nstal l i ng di stri butor.
(2) Check posi ti on of sl ot on oi l pump gear. I t
shoul d be just sl i ghtl y before (countercl ockwi se of)
the 11 ocl ock posi ti on (Fi g. 39). I f not, pl ace a fl at
bl ade screwdri ver i nto oi l pump gear and rotate i t
i nto proper posi ti on.
(3) Factory repl acement di stri butors are equi pped
wi th a pl asti c al i gnment pi n al ready i nstal l ed (Fi g.
Fig. 37 Distributor 4.0L EngineTypical
CAMSHAFT POSITION SEN- SOR HOUSING FORK WITH SLOT DRIVE GEAR ROLL PIN WASHER GASKET HOLDDOWNCLAMP HOLDDOWNBOLT
SHAFT
Fig. 38 Align Timing Marks4.0L Engine
CRANKSHAFT VIBRATION DAMPER TIMING MARK
36). Thi s pi n i s used to temporari l y hol d the rotor to
the cyl i nder number 1 fi ri ng posi ti on duri ng di stri b-
utor i nstal l ati on. I f thi s pi n i s i n pl ace, proceed to
Step 8. I f not, proceed to next step.
(4) I f ori gi nal di stri butor i s to be rei nstal l ed, such
as duri ng engi ne overhaul , the pl asti c pi n wi l l not be
avai l abl e. A 3/16 i nch dri ft pi n punch tool may be
substi tuted for the pl asti c pi n.
(5) Remove camshaft posi ti on sensor from di stri b-
utor housi ng. Li ft strai ght up.
(6) Four di fferent al i gnment hol es are provi ded on
the pl asti c ri ng (Fi g. 40). Note that 2.5L and 4.0L
engines have different alignment holes (Fig.
40).
(7) Rotate di stri butor shaft and i nstal l pi n punch
tool through proper al i gnment hol e i n pl asti c ri ng
(Fi g. 40) and i nto mati ng access hol e i n di stri butor
housi ng. Thi s wi l l prevent di stri butor shaft and rotor
from rotati ng.
(8) Cl ean di stri butor mounti ng hol e area of engi ne
bl ock.
(9) I nstal l new di stri butor-to-engi ne bl ock gasket
(Fi g. 37).
(10) I nstal l rotor to di stri butor shaft.
Pre-posi ti on di stri butor i nto engi ne whi l e hol di ng
centerl i ne of base sl ot i n 1 ocl ock posi ti on (Fi g. 41).
Conti nue to engage di stri butor i nto engi ne. The rotor
and di stri butor wi l l rotate cl ockwi se duri ng i nstal l a-
ti on. Thi s i s due to the hel i cal cut gears on the di s-
tri butor and camshaft. When di stri butor i s ful l y
seated to engi ne bl ock, the centerl i ne of base sl ot
shoul d be al i gned to cl amp bol t mounti ng hol e on
engi ne (Fi g. 42). The rotor shoul d al so be poi nted at
5 ocl ock posi ti on.
I t may be necessary to rotate rotor and di stri butor
shaft (very sl i ghtl y) to engage di stri butor shaft wi th
sl ot i n oi l pump gear. The same may have to be done
to engage di stri butor gear wi th camshaft gear.
The distributor is correctly installed when:
the rotor i s poi nted at 5 ocl ock posi ti on.
the pl asti c al i gnment pi n (or pi n punch tool ) i s
sti l l i nstal l ed to di stri butor.
the number 1 cyl i nder pi ston i s set at top dead
center (TDC) (compressi on stroke).
the centerl i ne of the sl ot at base of di stri butor i s
al i gned to centerl i ne of di stri butor hol ddown bol t
hol e on engi ne. I n thi s posi ti on, the hol ddown bol t
shoul d easi l y pass through sl ot and i nto engi ne.
Fig. 39 Slot At 11 Oclock Position4.0LEngine
FRONT 11 OCLOCK POSITION OIL PUMP SLOT
Fig. 40 Pin Alignment Holes4.0L Engine
DISTRIBUTOR HOUSING (TOP VIEW) PULSE RING 4.0L 6CYLIN- DER ENGINE ALIGN. HOLE 2.5L 4CYLIN- DER ENGINE ALIGN. HOLE MATING ACCESS HOLE IN DISTRIBUTOR HOUSING PLASTIC RING
Fig. 41 Distributor Pre-position4.0LEngines
1 OCLOCK POSITION FRONT BASE SLOT DISTRIBUTOR BASE
No adjustments are necessary. Proceed to next
step.
(11) I nstal l di stri butor hol ddown cl amp and bol t.
Ti ghten bol t to 23 Nm (17 ft. l bs.) torque.
(12) Remove pi n punch tool from di stri butor. Or, i f
pl asti c al i gnment pi n was used, remove i t strai ght
down from bottom of di stri butor. Di scard pl asti c pi n.
(13) I f removed, i nstal l camshaft posi ti on sensor to
di stri butor. Al i gn wi ri ng harness grommet to notch i n
di stri butor housi ng.
(14) I nstal l rotor.
CAUTION: If distributor cap is incorrectly posi-
tioned on distributor housing, the cap or rotor may
be damaged when engine is started.
(15) I nstal l di stri butor cap. Ti ghten di stri butor cap
hol ddown screws to 3 Nm (26 i n. l bs.) torque.
(16) I f removed, i nstal l spark pl ug cabl es to di s-
tri butor cap. For proper fi ri ng order, refer to Speci fi -
cati ons secti on at end of thi s group. See Engi ne
Fi ri ng Order.
(17) Connect di stri butor wi ri ng harness to mai n
engi ne harness.
Refer to Group 14, Fuel System for procedures.
IGNITION SWITCH AND KEY CYLINDER
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal .
KEY CYLINDER REMOVAL
(2) I f equi pped wi th ti l t col umn, remove ti l t l ever
by turni ng i t countercl ockwi se.
(3) Remove upper and l ower covers (shrouds) from
steeri ng col umn (Fi g. 43).
(4) I f equi pped wi th automati c transmi ssi on, pl ace
shi fter i n PARK posi ti on.
(5) A retai ni ng pi n (Fi g. 44) i s l ocated at si de of
key cyl i nder assembl y.
(a) Rotate key to RUN posi ti on.
(b) Press i n on retai ni ng pi n whi l e pul l i ng key
cyl i nder from i gni ti on swi tch.
Fig. 42 Distributor Engaged Position4.0LEngine
DISTRIBUTOR BASE SLOT CLAMP BOLT MOUNTING HOLE (ON ENGINE) DISTRIBUTOR BASE FRONT
Fig. 43 Shroud Removal/InstallationTypical
NUT STEERING WHEEL TILT LEVER UPPER SHROUD PANEL BRACKET SPACER NUT LOWER SHROUD CLOCK SPRING
Fig. 44 Retaining Pin
IGNITION SWITCH
KEY/KEY CYLINDER (RUN POSITION)
IGNITION SWITCH REMOVAL
(1) Remove key l ock cyl i nder. Refer to previ ous
steps.
(2) Remove 3 i gni ti on swi tch mounti ng screws
(Fi g. 45). Use tamper proof torx bi t (Snap-On
SDMTR10 or equi val ent) to remove screws.
(3) Gentl y pul l swi tch away from col umn. Rel ease
connector l ocks on 7-termi nal wi ri ng connector at
i gni ti on swi tch and remove connector (Fi g. 46).
(4) Rel ease connector l ock on 4-termi nal hal o l amp
wi ri ng connector and remove connector (Fi g. 46).
IGNITION SWITCH AND KEY CYLINDER
INSTALLATION
I f i nstal l i ng ignition key lock cylinder only,
proceed to fol l owi ng steps 2, 3 and 4. Al so refer to fol -
l owi ng steps 12 through 18. I f i nstal l i ng both swi tch
and key cyl i nder, refer to steps 1 through 18.
(1) Rotate fl ag (Fi g. 47) on rear of i gni ti on swi tch
unti l i n RUN posi ti on. Thi s step must be done to
al l ow tang (Fi g. 48) on key cyl i nder to fi t i nto sl ots
(Fi g. 45) wi thi n i gni ti on swi tch.
(2) Wi th key i nto i gni ti on key cyl i nder, rotate key
cl ockwi se unti l retai ni ng pi n can be depressed (Fi g.
48) or (Fi g. 49).
(3) I nstal l key cyl i nder i nto i gni ti on swi tch by
al i gni ng retai ni ng pi n i nto retai ni ng pi n sl ot (Fi g.
49). Push key cyl i nder i nto swi tch unti l retai ni ng pi n
engages. After pi n engages, rotate key to OFF or
LOCK posi ti on.
(4) Check for proper retenti on of key cyl i nder by
attempti ng to pul l cyl i nder from swi tch.
Fig. 45 Switch Mounting Screws
IGNITION SWITCH
SLOTS NOT ALIGNED
SLOTS ALIGNED
( )
Fig. 46 Ignition Switch and Halo Lamp Connectors
KEY-IN SWITCH & HALO LIGHT MULTI-FUNCTION SWITCH TURN SIGNAL SWITCH & LEVER IGNITION SWITCH SPEED CONTROL
Fig. 47 Flag in RUN Position
REAR OF IGNITION SWITCH
PARK LOCK DOWEL PIN (RUN POSITION)
Fig. 48 Key CylinderRear View
IGNITION KEY LOCK CYLIN- DER
PUSH PIN
(5) Automati c Transmi ssi on Onl y: Before attachi ng
i gni ti on swi tch to steeri ng col umn, the transmi ssi on
shi fter must be i n PARK posi ti on. The park l ock
dowel pi n on rear of i gni ti on swi tch (Fi g. 50) must
al so be properl y i ndexed i nto the park l ock l i nkage
(Fi g. 51) before i nstal l i ng swi tch.
(6) The fl ag at rear of i gni ti on swi tch (Fi g. 50)
must be properl y i ndexed i nto steeri ng col umn before
i nstal l i ng swi tch. Thi s fl ag i s used to operate the
steeri ng wheel l ock l ever i n steeri ng col umn (Fi g. 52).
Thi s l ever al l ows steeri ng wheel posi ti on to be l ocked
when key swi tch i s i n LOCK posi ti on.
(7) Pl ace i gni ti on swi tch i n LOCK posi ti on. The
swi tch i s i n the LOCK posi ti on when col umn l ock
fl ag i s paral l el to i gni ti on swi tch termi nal s (Fi g. 50).
(8) Automati c Transmi ssi on Onl y: Appl y a l i ght
coati ng of grease to park l ock dowel pi n and park
l ock sl i der l i nkage. Before i nstal l i ng swi tch, push the
park l ock sl i der l i nkage (Fi g. 51) forward unti l i t bot-
toms. Do a fi nal posi ti oni ng by pul l i ng i t rearward
about one-quarter i nch.
(9) Appl y a l i ght coati ng of grease to both col umn
l ock fl ag and shaft at end of fl ag.
(10) Pl ace i gni ti on swi tch i nto openi ngs on steeri ng
col umn.
(a) Automati c Transmi ssi on Onl y: Be sure park
l ock dowel pi n on rear of i gni ti on swi tch enters sl ot
i n park l ock sl i der l i nkage (Fi g. 51).
(b) Be sure fl ag on rear of swi tch i s posi ti oned
above steeri ng wheel l ock l ever (Fi g. 52).
(c) Al i gn dowel pi ns on rear of swi tch i nto hol es
on si de of steeri ng col umn.
Fig. 49 Installing Key Cylinder Into Switch
IGNITION SWITCH
DRIVER
IGNITION KEY LOCK CYLIN- DER
Fig. 50 Ignition Switch View From Column
REAR OF IGNITION SWITCH
PARK LOCK DOWEL PIN (LOCK POSITION)
Fig. 51 Park Lock Linkage
AutomaticTransmissionTypical
DOWEL LOCATING HOLES (2)
PARK LOCK SLIDER LINK- AGE
Fig. 52 Steering Wheel Lock Lever
STEERING COLUMN
STEERING WHEEL LOCK LEVER
(d) I nstal l 3 i gni ti on swi tch mounti ng screws.
Ti ghten screws to 3 Nm .5 Nm (26 i n. l bs. 4
i n. l bs.) torque.
(11) Connect el ectri cal connectors to i gni ti on
swi tch and hal o l amp. Make sure that swi tch l ocki ng
tabs are ful l y seated i n wi ri ng connectors.
(12) I nstal l steeri ng col umn covers (shrouds).
Ti ghten screws to 2 Nm (17 i n. l bs.) torque.
(13) I nstal l ti l t col umn l ever (i f equi pped).
(14) Connect negati ve cabl e to battery.
(15) Check for proper operati on of hal o l i ght.
(16) Automati c Transmi ssi on Onl y: Shi fter shoul d
l ock i n PARK posi ti on when key i s i n LOCK posi ti on
(i f equi pped wi th shi ft l ock devi ce). Shi fter shoul d
unl ock when key rotated to ON posi ti on.
(17) Check for proper operati on of i gni ti on swi tch
i n ACCESSORY, LOCK, OFF, ON, RUN, and START
posi ti ons.
(18) Steeri ng wheel shoul d l ock when key i s i n
LOCK posi ti on. Rotate steeri ng wheel to veri fy.
Steeri ng wheel shoul d unl ock when key i s rotated to
ON posi ti on.
SHIFTER/IGNITION INTERLOCK
On model s equi pped wi th an automati c transmi s-
si on, a cabl e connects the i gni ti on swi tch wi th the
fl oor shi ft l ever. The shi fter wi l l be l ocked i n the
PARK posi ti on when the i gni ti on key i s i n the LOCK
or ACCESSORY posi ti ons. The cabl e can be adjusted
or repl aced. Refer to Group 21, Transmi ssi ons for
procedures. The i gni ti on i nterl ock devi ce wi thi n the
steeri ng col umn i s not servi ceabl e. I f servi ce i s nec-
essary, the steeri ng col umn must be repl aced. Refer
to Group 19, Steeri ng for procedures.
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.
IGNITION TIMING
I gni ti on ti mi ng i s not adjustabl e on any engi ne.
Refer to I gni ti on Ti mi ng i n the Di agnosti cs/Servi ce
Procedures secti on of thi s group for more i nforma-
ti on.
ENGINE FIRING ORDER4. 0L 6-CYLINDER
ENGINE
ENGINE FIRING ORDER5. 2L/5. 9L V-8 ENGINES
TORQUE CHART
DESCRIPTION TORQUE
Crankshaft Posi ti on Sensor
4.0L Engi ne . . . . . . . . . . . . . . . 7 Nm (60 i n. l bs.)
Crankshaft Posi ti on Sensor
5.2L/5.9L Engi ne . . . . . . . . . . . 8 Nm (70 i n. l bs.)
Di stri butor Hol d Down Bol t
Al l Engi nes . . . . . . . . . . . . . . . 23 Nm (17 ft. l bs.)
I gni ti on Coi l Mounti ng (i f tapped
bol ts are used) . . . . . . . . . . . . . 5 Nm (50 i n. l bs.)
I gni ti on Coi l Mounti ng
(i f nuts/bol ts are used) . . . . . 11 Nm (100 i n. l bs.)
Powertrai n Control Modul e (PCM)
Mounti ng Screws . . . . . . . . . . . . 1 Nm (9 i n. l bs.)
Spark Pl ugsAl l Engi nes . . . . . 41 Nm (30 ft. l bs.)
FRONT FIRING ORDER: 1 5 3 6 2 4 CLOCK- WISE ROTA- TION FRONT OFENGINE CLOCKWISE ROTATION 1-8-4-3-6-5-7-2
SPARK PLUGS SPARK PLUG CABLE RESISTANCE
IGNITION COIL RESISTANCE
ENGINE
PLUG TYPE ELECTRODE GAP
4.0L 6-CYL. RC12LYC 0.89 mm (.035 in.)
5.2L V-8 RC12LC4 1.01 mm (.040 in.)
5.9L V-8 RC12YC 0.89 mm (.035 in.)
MINIMUM MAXIMUM
COIL TOYODENSO DIAMOND
Primary Resistance .95 - 1.20 Ohms .96 - 1.18 Ohms
Secondary Resistance at 70- 80F 11,300 - 13,300 Ohms 11,300 - 15,300 Ohms
INSTRUMENT PANEL SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
BODY CONTROL MODULE . . . . . . . . . . . . . . . . 4
GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GRAPHIC DISPLAY MODULE . . . . . . . . . . . . . . 3
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . 4
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 2
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 2
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 4
VEHICLE INFORMATION CENTER . . . . . . . . . . 3
AIRBAG INDICATOR LAMP . . . . . . . . . . . . . . . . 6
ANTI-LOCK BRAKE SYSTEM LAMP . . . . . . . . . . 7
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . 7
CHECK GAUGES LAMP . . . . . . . . . . . . . . . . . . . 7
CLUSTER ILLUMINATION LAMP . . . . . . . . . . . . 7
COOLANT TEMPERATURE GAUGE . . . . . . . . . . 5
CRUISE-ON INDICATOR LAMP . . . . . . . . . . . . . 8
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEADLAMP HIGH BEAM INDICATOR LAMP . . . 8
LOW FUEL WARNING LAMP . . . . . . . . . . . . . . . 8
MALFUNCTION INDICATOR LAMP . . . . . . . . . . 8
MASTER LIGHTING INDICATOR LAMP . . . . . . . 8
ODOMETER AND TRIP ODOMETER . . . . . . . . . 5
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . . 5
SEAT BELT REMINDER LAMP . . . . . . . . . . . . . . 9
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 6
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . . 9
UPSHIFT INDICATOR LAMP . . . . . . . . . . . . . . . 9
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WAIT-TO-START LAMP . . . . . . . . . . . . . . . . . . . 9
WATER-IN-FUEL LAMP . . . . . . . . . . . . . . . . . . . 9
AIRBAG INDICATOR LAMP . . . . . . . . . . . . . . . 12
ANTI-LOCK BRAKE SYSTEM LAMP . . . . . . . . . 12
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . 13
CHECK GAUGES LAMP . . . . . . . . . . . . . . . . . . 13
CLUSTER ILLUMINATION LAMP . . . . . . . . . . . 13
COOLANT TEMPERATURE GAUGE . . . . . . . . . 10
CRUISE-ON INDICATOR LAMP . . . . . . . . . . . . 14
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . 10
GRAPHIC DISPLAY MODULE . . . . . . . . . . . . . 14
HEADLAMP HIGH BEAM INDICATOR LAMP . . 15
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . 10
LOW FUEL WARNING LAMP . . . . . . . . . . . . . . 16
MASTER LIGHTING INDICATOR LAMP . . . . . . 16
ODOMETER AND TRIP ODOMETER . . . . . . . . 11
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . 11
SEAT BELT REMINDER LAMP . . . . . . . . . . . . . 17
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 11
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 11
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . 17
UPSHIFT INDICATOR LAMP . . . . . . . . . . . . . . 17
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WAIT-TO-START LAMP . . . . . . . . . . . . . . . . . . 20
WATER-IN-FUEL LAMP . . . . . . . . . . . . . . . . . . 20
SERVICE PROCEDURES
BODY CONTROL MODULE . . . . . . . . . . . . . . . 28
CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . . . . . 30
CLUSTER BEZEL . . . . . . . . . . . . . . . . . . . . . . . 24
CLUSTER BULB . . . . . . . . . . . . . . . . . . . . . . . . 26
CLUSTER LENS, HOOD, AND MASK . . . . . . . . 25
COWL TOP TRIM PANEL . . . . . . . . . . . . . . . . . 32
GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GLOVE BOX COMPONENTS . . . . . . . . . . . . . . 31
GLOVE BOX LAMP AND SWITCH . . . . . . . . . . 29
GLOVE BOX LATCH STRIKER . . . . . . . . . . . . . 29
GLOVE BOX MODULE . . . . . . . . . . . . . . . . . . . 28
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 31
GRAPHIC DISPLAY MODULE AND VEHICLE
INFORMATION CENTER . . . . . . . . . . . . . . . . 28
INBOARD SWITCH POD . . . . . . . . . . . . . . . . . 27
INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . 33
INSTRUMENT PANEL CENTER BEZEL . . . . . . 30
INSTRUMENT PANEL TOP PAD . . . . . . . . . . . . 32
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 33
KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . . 24
OUTBOARD SWITCH POD . . . . . . . . . . . . . . . 26
POWER OUTLET DOOR . . . . . . . . . . . . . . . . . 30
POWER OUTLET . . . . . . . . . . . . . . . . . . . . . . . 30
SWITCH POD BEZEL . . . . . . . . . . . . . . . . . . . . 24
ZG INSTRUMENT PANEL SYSTEMS 8E - 1
GENERAL INFORMATION
INTRODUCTION
Thi s group i s responsi bl e for coveri ng the vehi cl e
i nstrument panel . However, because the i nstrument
panel serves as the command center of the vehi cl e, i t
i s a very compl ex uni t. The i nstrument panel i s
desi gned to house the control s and moni tors for stan-
dard and opti onal powertrai ns, cl i mate control sys-
tems, audi o systems, l i ghti ng systems, safety
systems, and many other comfort or conveni ence
i tems. I t i s al so desi gned so that al l of the control s
and moni tors can be safel y reached and vi ewed by
the vehi cl e operator, whi l e sti l l al l owi ng rel ati ve ease
of access to these i tems for servi ce.
Compl ete servi ce i nformati on coverage for al l of the
systems and components housed i n the i nstrument
panel i n thi s secti on of the servi ce manual woul d not
be practi cal . I t woul d resul t i n a great deal of dupl i -
cati on and make thi s group too l arge for the i nforma-
ti on to be easi l y accessed and used. Therefore, the
i nformati on found i n thi s group has been l i mi ted as
fol l ows:
General I nformati on - Covers non-el ectri cal com-
ponents and features of the i nstrument panel that
are not rel ated to other systems.
Descri pti on and Operati on - Covers gauges and
thei r sendi ng uni ts, warni ng l amps and thei r
swi tches, and i nstrument panel i l l umi nati on l amps.
Di agnosi s and Testi ng - Covers gauges and thei r
sendi ng uni ts, warni ng l amps and thei r swi tches,
and i nstrument panel i l l umi nati on l amps.
Removal and I nstal l ati on - Covers components
i nstal l ed on or i n the i nstrument panel that requi re
removal for di agnosi s or servi ce of i nstrument panel
components covered i n thi s group.
For more i nformati on on components or systems
not covered above, refer to the proper group i n thi s
manual . I f you are uncertai n as to the proper group,
refer to the Component and System I ndex at the
back of thi s manual . Refer to Group 8W - Wi ri ng
Di agrams for compl ete ci rcui t descri pti ons and di a-
grams.
INSTRUMENT PANEL
Modul ar i nstrument panel constructi on al l ows al l
of the gauges and control s to be servi ced from the
front of the panel . I n addi ti on, most of the i nstru-
ment panel wi ri ng or heati ng and ai r condi ti oni ng
components can be accessed wi thout compl ete i nstru-
ment panel removal . I f necessary, the i nstrument
panel can be rol l ed-down and removed from the vehi -
cl e as an assembl y.
Removal of the swi tch pod bezel s al l ows access to
most swi tches and the cl i mate control s. Removal of
the i nstrument cl uster bezel al l ows access to the
cl uster assembl y and the radi o. Removal of the cl us-
ter assembl y al l ows access to the i ndi vi dual gauges,
i l l umi nati on and i ndi cator l amp bul bs, and most of
the i nstrument panel wi ri ng.
Removal of the steeri ng col umn cover/knee bl ocker
provi des access to the steeri ng col umn mounts, the
body control modul e, the gearshi ft i nterl ock mecha-
ni sm, and addi ti onal i nstrument panel and steeri ng
col umn wi ri ng. Removal of the gl ove box modul e and
center bezel uni t al l ows access to the Vehi cl e I nfor-
mati on Center (VI C), Graphi c Di spl ay Modul e
(GDM), addi ti onal i nstrument panel wi ri ng, the
i n-vehi cl e temperature sensor, and other heati ng and
ai r condi ti oni ng components.
Removal of the i nstrument panel cowl top tri m
panel al l ows access to the i nstrument panel speak-
ers, the sol ar sensor, and the automati c headl amp
l i ght sensor/vehi cl e theft securi ty system l amp.
Removal of the i nstrument panel top pad al l ows
access to the passenger si de ai rbag modul e.
INSTRUMENT CLUSTER
One basi c i nstrument cl uster opti on i s offered on
Grand Cherokee model s. Thi s cl uster i s an el ectrome-
chani cal uni t that uti l i zes i ntegrated ci rcui try and
i nformati on carri ed on the Chrysl er Col l i si on Detec-
ti on (CCD) data bus network for control of al l gauges
and most i ndi cator l amps. Thi s cl uster al so i ncorpo-
rates a vacuum fl uorescent di spl ay tube for the di gi -
tal odometer and tri p odometer di spl ay functi ons.
Some vari ati ons of the cl uster exi st due to opti onal
equi pment and regul atory requi rements.
The cl uster i ncl udes the fol l owi ng anal og gauges:
Fuel gauge
Oi l pressure gauge
Speedometer
Tachometer
Vol tmeter.
Thi s cl uster i ncl udes provi si ons for the fol l owi ng
i ndi cator l amps:
Ai rbag i ndi cator l amp
Anti -l ock brake system l amp
Brake warni ng l amp
8E - 2 INSTRUMENT PANEL SYSTEMS ZG
Check gauges l amp
Crui se-on i ndi cator l amp
Headl amp hi gh beam i ndi cator l amp
Low fuel warni ng l amp
Mal functi on i ndi cator (Check Engi ne) l amp
Master l i ghti ng i ndi cator l amp
Seat bel t remi nder l amp
Turn si gnal i ndi cator l amps
Upshi ft i ndi cator l amp (manual transmi ssi on)
Wai t-to-start l amp (di esel engi ne)
Water-i n-fuel l amp (di esel engi ne).
GRAPHIC DISPLAY MODULE
A Graphi c Di spl ay Modul e (GDM) i s standard
equi pment on al l four-wheel dri ve Grand Cherokee
model s, unl ess the vehi cl e i s equi pped wi th the
opti onal Vehi cl e I nformati on Center (VI C). The GDM
i s mounted i n the l ower center stack area of the
i nstrument panel , above the ash recei ver and bel ow
the heater-A/C control s. Two-wheel dri ve Grand
Cherokee model s have a storage bi n i nstal l ed i n
pl ace of the GDM as standard equi pment.
The GDM di spl ay consi sts of a back-l i t screen wi th
a vehi cl e outl i ne. The two rear wheel s of the vehi cl e
are i l l umi nated by a l amp when the transfer case i s
engaged i n any two-wheel dri ve operati ng mode. The
two front wheel s are al so i l l umi nated when the
transfer case i s engaged i n any four-wheel dri ve oper-
ati ng mode.
The GDM al so has up to three l amps, whi ch i ndi -
cate whether the four-wheel dri ve mode sel ected i s
Lo, Part-Ti me, or Ful l -Ti me. The number of opera-
ti onal i ndi cator l amps may vary, dependi ng upon the
opti onal four-wheel dri ve transfer case i n the vehi cl e.
A swi tch on the transfer case i s hard-wi red to the
GDM to i l l umi nate the proper wheel s and i ndi cator
l amps.
The GDM bul bs can be servi ced. However, i f any
other part of the GDM i s damaged or faul ty, the
enti re GDM must be repl aced.
VEHICLE INFORMATION CENTER
The Vehi cl e I nformati on Center (VI C) i s an avai l -
abl e opti on on Grand Cherokee model s. The VI C
modul e repl aces the standard equi pment Graphi c
Di spl ay Modul e. The VI C i s mounted i n the l ower
center stack area of the i nstrument panel , above the
ash recei ver and bel ow the heater-A/C control s.
The VI C consi sts of a mul ti col ored vacuum fl uores-
cent di spl ay screen wi th a vehi cl e outl i ne. The VI C i s
abl e to di spl ay four functi ons i n a choi ce of fi ve l an-
guages. The di spl ay functi ons i ncl ude:
Current ti me (12 or 24 hour cl ock), day, and date
Moni tor speci fi c vehi cl e operati ng systems and
al ert the dri ver of a mal functi on i n a moni tored sys-
tem
Provi de servi ce remi nders or the di stance to the
next servi ce i nterval
The current transfer case mode of operati on
(four-wheel dri ve model s).
The di spl ay l anguage choi ces i ncl ude:
Engl i sh
French
German
I tal i an
Spani sh.
The VI C recei ves i nput from hard-wi red sensors
and over the Chrysl er Col l i si on Detecti on (CCD) data
bus network. I n response to these i nputs the VI C
offers a combi nati on of graphi c and message di spl ays,
and provi des requests for audi bl e chi me al erts to the
Body Control Modul e (BCM) on the CCD data bus.
Refer to the owners manual for more i nformati on
on the VI C control s, operati on, and setti ng proce-
dures. For di agnosi s of the VI C modul e or the CCD
data bus, refer to the proper Body Di agnosti c Proce-
dures manual . The VI C modul e cannot be repai red. I f
damaged or faul ty, the enti re modul e must be
repl aced.
GAUGE
Wi th the i gni ti on swi tch i n the On or Start posi -
ti ons, vol tage i s suppl i ed to al l gauges through the
i nstrument cl uster el ectroni c ci rcui t board. Wi th the
i gni ti on swi tch i n the Off posi ti on, vol tage i s not sup-
pl i ed to the gauges. The gauges do not accuratel y
i ndi cate any vehi cl e condi ti on unl ess the i gni ti on
swi tch i s i n the On or Start posi ti ons.
Al l gauges, except the odometer, are ai r core mag-
neti c uni ts. Two fi xed el ectromagneti c coi l s are
l ocated wi thi n the gauge. These coi l s are wrapped at
ri ght angl es to each other around a movabl e perma-
nent magnet. The movabl e magnet i s suspended
wi thi n the coi l s on one end of a shaft. The gauge nee-
dl e i s attached to the other end of the shaft.
One of the coi l s has a fi xed current fl owi ng
through i t to mai ntai n a constant magneti c fi el d
strength. Current fl ow through the second coi l
changes, whi ch causes changes i n i ts magneti c fi el d
strength. The current fl owi ng through the second coi l
i s changed by the i nstrument cl uster el ectroni c ci r-
cui try i n response to messages recei ved on the
Chrysl er Col l i si on Detecti on (CCD) data bus network.
The gauge needl e moves as the movabl e permanent
magnet al i gns i tsel f to the changi ng magneti c fi el ds
created around i t by the el ectromagnets. These
gauges al so feature a smal l fi xed permanent magnet
whi ch wi l l cause the gauge needl es to return to zero
after the i gni ti on swi tch i s turned to the Off posi ti on.
INDICATOR LAMP
I ndi cator l amps are l ocated i n the i nstrument cl us-
ter, and i n the Graphi c Di spl ay Modul e (GDM) or the
Vehi cl e I nformati on Center (VI C). Those l amps
wi thi n the i nstrument cl uster are served by the cl us-
ter ci rcui t board and wi re harness connectors. Those
l amps l ocated i n the GDM or VI C modul es are served
by the GDM or VI C ci rcui t board and wi re harness
connectors.
Most of the i ndi cator l amps i n the i nstrument cl us-
ter and VI C modul e are control l ed by the i nstrument
cl uster or VI C modul e el ectroni c ci rcui try i n response
to messages recei ved over the Chrysl er Col l i si on
Detecti on (CCD) data bus network from the Body
Control Modul e (BCM), Powertrai n Control Modul e
(PCM), and Ai rbag Control Modul e (ACM). Onl y the
anti -l ock brake system l amp, four-wheel dri ve i ndi ca-
tor l amps, l amp outage warni ng l amp, l ow cool ant
l evel warni ng l amp, l ow washer fl ui d warni ng l amp,
master l i ghti ng i ndi cator l amp, and turn si gnal i ndi -
cator l amps are hard-wi red.
BODY CONTROL MODULE
A Body Control Modul e (BCM) i s used on thi s
model to control and i ntegrate many of the el ectroni c
functi ons and features i ncl uded on the vehi cl e. The
BCM contai ns a central processi ng uni t and i nter-
faces wi th other modul es i n the vehi cl e on the
The CCD data bus network al l ows the shari ng of
sensor i nformati on. Thi s hel ps to reduce wi re har-
ness compl exi ty, reduce i nternal control l er hardware,
and reduce component sensor current l oads. At the
same ti me, thi s system provi des i ncreased rel i abi l i ty,
enhanced di agnosti cs, and al l ows the addi ti on of
many new feature capabi l i ti es.
Some of the functi ons and features that the BCM
supports or control s, i ncl ude:
Chi mes
Automati c headl amp control
Headl amp del ay
Headl amps on wi th i gni ti on off and dri ver door
open warni ng
Key i n i gni ti on wi th i gni ti on off and dri ver door
open warni ng
Automati c funeral or parade mode
Panel l amp di mmi ng
Vehi cl e Theft Securi ty System (VTSS)
Vehi cl e i mmobi l i zer system
I l l umi nated entry
Heated rear wi ndow and heated outsi de mi rror
control
I ntermi ttent wi pe control
Moni tori ng and transmi tti ng door, hood, l i ftgate,
l i ftgl ass ajar data
Moni tori ng and transmi tti ng outsi de ambi ent
temperature data
Moni tori ng and transmi tti ng ai r condi ti oni ng
sel ect swi tch data
Courtesy l amp ti me-out
Gul f coast country over-speed warni ng
Door l ock i nhi bi t
El ectroni c odometer and tri p odometer
Check gauges l amp
Hi gh beam i ndi cator l amp
Seatbel t remi nder l amp and chi me
Speed sensi ti ve i ntermi ttent wi pe
Fog l amp control
El ectromechani cal i nstrument cl uster
BCM di agnosti c support
Vehi cl e I nformati on Center (VI C) support
Rol l i ng door l ocks
Horn chi rp upon door l ock wi th Remote Keyl ess
Entry (RKE)(programmabl e)
Low fuel warni ng chi me (programmabl e)
Headl i ghts on wi th wi pers (programmabl e - wi th
automati c headl amps onl y)
The BCM i s mounted under the dri ver si de out-
board end of the i nstrument panel , behi nd the i nstru-
ment panel support armature and bel ow the
outboard swi tch pod. For di agnosi s of the BCM or the
CCD data bus, refer to the proper Body Di agnosti c
Procedures manual . The BCM can onl y be servi ced
by an authori zed el ectroni c repai r stati on. Refer to
the l atest Warranty Pol i ci es and Procedures manual
for a current l i sti ng of authori zed el ectroni c repai r
stati ons.
JUNCTION BLOCK
The juncti on bl ock i s mounted on the ri ght cowl
si de ki ck panel bel ow the ri ght end of the i nstrument
panel . I t i s conceal ed behi nd the ri ght cowl si de tri m.
The juncti on bl ock serves to si mpl i fy and central i ze
numerous el ectri cal components.
The juncti on bl ock has cavi ti es for up to twenty-
two bl ade-type fuses, three ci rcui t breakers, si x I SO
mi cro-rel ays, and an el ectroni c combi nati on fl asher
uni t. I t al so el i mi nates the need for numerous spl i ce
connecti ons and serves i n the pl ace of a bul khead
connector between the engi ne compartment, i nstru-
ment panel , and body wi re harnesses.
The ri ght cowl si de tri m panel has a snap-fi t access
cover that can be removed for servi ce of the juncti on
bl ock fuses, but the cowl si de tri m panel must be
removed for servi ce of other juncti on bl ock compo-
nents. The juncti on bl ock cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
COOLANT TEMPERATURE GAUGE
The cool ant temperature gauge gi ves an i ndi cati on
of the engi ne cool ant temperature. The i nstrument
cl uster ci rcui try control s the gauge poi nter posi ti on.
The i nstrument cl uster ci rcui try cal cul ates the
proper gauge poi nter posi ti on based upon an engi ne
cool ant temperature message recei ved from the Pow-
ertrai n Control Modul e (PCM) on the Chrysl er Col l i -
si on Detecti on (CCD) data bus.
The PCM uses an i nput from the engi ne cool ant
temperature sensor and i nternal programmi ng to
deci de what engi ne cool ant temperature message i s
requi red. The PCM then sends the proper message to
the i nstrument cl uster and the Body Control Modul e
(BCM) on the CCD data bus.
The BCM moni tors the PCM cool ant temperature
messages. I f the PCM message i ndi cates that cool ant
temperature i s hi gh or cri ti cal , the BCM sends a
message to the i nstrument cl uster to turn on the
Check Gauges l amp and to dri ve the cool ant temper-
ature gauge needl e to the correspondi ng hi gh or cri t-
i cal posi ti on of the gauge scal e.
The engi ne cool ant temperature sensor i s i nstal l ed
i n a threaded hol e that penetrates a cool ant passage
of the engi ne. I t i s a thermi stor-type sensor that
changes i ts i nternal resi stance wi th changes i n
engi ne cool ant temperature. Refer to Group 14 - Fuel
Systems for more i nformati on on the PCM and the
cool ant temperature sensor.
FUEL GAUGE
The fuel gauge gi ves an i ndi cati on of the l evel of
fuel i n the fuel tank. The i nstrument cl uster ci rcui try
control s the gauge poi nter posi ti on. The i nstrument
cl uster ci rcui try cal cul ates the proper gauge poi nter
posi ti on based upon a fuel l evel message recei ved
from the Powertrai n Control Modul e (PCM) on the
Chrysl er Col l i si on Detecti on (CCD) data bus.
The PCM uses an i nput from the fuel gauge send-
i ng uni t and i nternal programmi ng to deci de what
fuel l evel message i s requi red. The PCM then sends
the proper message to the i nstrument cl uster on the
CCD data bus. I f the PCM detects a short or open i n
the fuel l evel sendi ng uni t ci rcui t, i t sends a message
on the CCD data bus that wi l l cause the i nstrument
cl uster ci rcui try to posi ti on the fuel gauge needl e at
the Empty stop.
The fuel gauge sendi ng uni t i s mounted to the el ec-
tri c fuel pump modul e l ocated i nsi de the fuel tank.
The sendi ng uni t has a fl oat attached to the end of a
swi ng-arm. The fl oat moves up or down wi thi n the
fuel tank as the fuel l evel changes. As the fl oat
moves, an el ectri cal contact on the pi vot end of the
swi ng-arm wi pes across a resi stor coi l , whi ch changes
the i nternal el ectri cal resi stance of the sendi ng uni t.
Refer to Group 14 - Fuel Systems for more i nforma-
ti on on the PCM and for the fuel gauge sendi ng uni t
servi ce procedures.
ODOMETER AND TRIP ODOMETER
The odometer and the tri p odometer share the
same vacuum fl uorescent di gi tal di spl ay tube i n the
i nstrument cl uster ci rcui t board. Each gi ves an i ndi -
cati on of the di stance the vehi cl e has travel l ed. How-
ever; by depressi ng the reset knob on the face of the
i nstrument cl uster, the di spl ay can be swi tched from
odometer to tri p odometer. Depressi ng the reset knob
for l onger than two seconds whi l e i n the tri p odome-
ter mode wi l l reset the tri p odometer to zero. The
odometer and tri p odometer di spl ay the di stance val -
ues that are recei ved from the Body Control Modul e
(BCM) on the Chrysl er Col l i si on Detecti on (CCD)
data bus.
The BCM uses an i nput from the Powertrai n Con-
trol Modul e (PCM) and i nternal programmi ng to cal -
cul ate the di stance val ue. The PCM uses an i nput
from the Vehi cl e Speed Sensor (VSS) to send a di s-
tance pul se si gnal to the BCM on the CCD data bus.
The BCM stores both the odometer and tri p odometer
di stance i nformati on and sends the proper val ue to
the i nstrument cl uster based upon i gni ti on key-on
and tri p odometer reset knob messages recei ved on
the CCD data bus.
I f the i nstrument cl uster i s not recei vi ng di stance
i nformati on on the CCD data bus when the i gni ti on
swi tch i s turned to the On posi ti on, the odometer di s-
pl ay wi l l remai n bl ank. I f the i nstrument cl uster
does not recei ve a di stance message on the CCD data
bus after the i gni ti on swi tch has been turned to the
On posi ti on, the i nstrument panel ci rcui try wi l l
i nsert the l ast normal l y di spl ayed di stance i n the
odometer di spl ay.
The VSS i s a hal l -effect sensor that i s i nstal l ed i n
the transmi ssi on (two-wheel dri ve) or transfer case
(four-wheel dri ve), and i s dri ven by the output shaft
through a speedometer pi ni on gear. I ncorrect ti re
si ze, i ncorrect axl e rati o, a faul ty or i ncorrect speed-
ometer pi ni on gear, or a faul ty VSS can each resul t
i n i naccurate odometer readi ngs. Refer to Group 14 -
Fuel Systems for more i nformati on on the PCM and
the VSS. Refer to Group 21 - Transmi ssi on for more
i nformati on on the speedometer pi ni on gear.
OIL PRESSURE GAUGE
The oi l pressure gauge gi ves an i ndi cati on of the
engi ne oi l pressure. The i nstrument cl uster ci rcui try
posi ti on based upon an engi ne oi l pressure message
recei ved from the Powertrai n Control Modul e (PCM)
on the Chrysl er Col l i si on Detecti on (CCD) data bus.
The PCM uses an i nput from the engi ne oi l pres-
sure sensor and i nternal programmi ng to deci de
what engi ne oi l pressure message i s requi red. The
PCM then sends the proper message to the i nstru-
ment cl uster and the Body Control Modul e (BCM) on
the CCD data bus.
The BCM moni tors the PCM engi ne oi l pressure
messages. I f the PCM message i ndi cates that engi ne
oi l pressure i s too l ow, the BCM sends a message to
the i nstrument cl uster to turn on the Check Gauges
l amp and to dri ve the oi l pressure gauge needl e to
the zero end of the gauge scal e.
The engi ne oi l pressure sensor i s i nstal l ed i n a
threaded hol e that penetrates an oi l passage of the
engi ne. The engi ne oi l pressure sensor contai ns a
fl exi bl e di aphragm and a vari abl e resi stor coi l . The
di aphragm moves i n response to changes i n the
engi ne oi l pressure, whi ch changes the i nternal el ec-
tri cal resi stance of the sensor. Refer to Group 14 -
the engi ne oi l pressure sensor.
SPEEDOMETER
The speedometer gi ves an i ndi cati on of the current
vehi cl e speed. The i nstrument cl uster ci rcui try con-
trol s the gauge poi nter posi ti on. The i nstrument cl us-
ter ci rcui try cal cul ates the proper gauge poi nter
posi ti on based upon a vehi cl e speed message recei ved
The PCM uses an i nput from the Vehi cl e Speed
Sensor (VSS) and i nternal programmi ng to deci de
what vehi cl e speed message i s requi red. The PCM
then sends the proper message to the i nstrument
cl uster on the CCD data bus.
i n i naccurate speedometer readi ngs. Refer to Group
14 - Fuel Systems for more i nformati on on the PCM
and the VSS. Refer to Group 21 - Transmi ssi on for
more i nformati on on the speedometer pi ni on gear.
TACHOMETER
The tachometer gi ves an i ndi cati on of the engi ne
speed i n revol uti ons-per-mi nute (rpm). The i nstru-
ment cl uster ci rcui try control s the gauge poi nter
posi ti on. The i nstrument cl uster ci rcui try cal cul ates
the proper gauge poi nter posi ti on based upon an
engi ne speed message recei ved from the Powertrai n
Control Modul e (PCM) on the Chrysl er Col l i si on
Detecti on (CCD) data bus.
The PCM uses an i nput from the crankshaft posi -
ti on sensor and i nternal programmi ng to deci de what
engi ne speed message i s requi red. The PCM then
sends the proper message to the i nstrument cl uster
on the CCD data bus.
The crankshaft posi ti on sensor i s i nstal l ed near the
rear of the engi ne, where i t i s ai med at the tri gger
wheel attached to the rear fl ange of the crankshaft.
For model s wi th a gasol i ne engi ne, refer to Group 8D
- I gni ti on Systems for more i nformati on on the
crankshaft posi ti on sensor. For model s wi th a di esel
engi ne, refer to Group 14 - Fuel Systems for more
i nformati on on the crankshaft posi ti on sensor.
VOLTMETER
The vol tmeter gi ves an i ndi cati on of the el ectri cal
system vol tage. The i nstrument cl uster ci rcui try con-
posi ti on based upon a system vol tage message
The PCM uses an i nput from the el ectri cal system
and i nternal programmi ng to deci de what system
vol tage message i s requi red. The PCM then sends
CCD data bus.
Refer to Group 14 - Fuel System for more i nforma-
ti on on the PCM. Refer to Group 8C - Chargi ng Sys-
tem for more i nformati on on chargi ng system
components and di agnosi s.
AIRBAG INDICATOR LAMP
The ai rbag i ndi cator l amp gi ves an i ndi cati on when
the ai rbag system i s faul ty or i noperati ve. The l amp
i s turned on by the i nstrument cl uster ci rcui try for
about seven seconds when the i gni ti on swi tch i s
turned to the On posi ti on as a bul b test. After the
bul b test, the l amp i s control l ed by the i nstrument
cl uster ci rcui try based upon a message recei ved from
the Ai rbag Control Modul e (ACM) on the Chrysl er
Col l i si on Detecti on (CCD) data bus.
The ACM conti nual l y moni tors the ai rbag system
ci rcui ts and sensors to deci de whether the system i s
i n good operati ng condi ti on. The ACM then sends the
proper message to the i nstrument cl uster on the
CCD data bus to turn the l amp on or off. I f the ACM
turns the l amp on after the bul b test, i t i ndi cates the
ACM has detected a system mal functi on and/or that
the ai rbag system has become i noperati ve. Each ti me
the i nstrument cl uster ci rcui try recei ves a l amp-on
message from the ACM, i t wi l l l i ght the l amp for
twel ve seconds or the durati on of the ai rbag system
mal functi on, whi chever i s l onger.
The ai rbag i ndi cator l amp al so has a l amp backup
feature. Fol l owi ng the seat bel t remi nder l amp di s-
pl ay functi on, i f an i noperati ve ai rbag warni ng l amp
ci rcui t was detected duri ng the bul b test sequence,
the i nstrument cl uster ci rcui try wi l l fl ash the seat
bel t remi nder l amp on and off for about twenty sec-
onds. I f the seat bel t remi nder l amp fl ashes l onger
than twenty seconds, or fl ashes at any ti me other
than about twenty seconds after the i ni ti al i gni -
ti on-on sequence, i t i ndi cates an ai rbag system faul t
has been detected and that the ai rbag i ndi cator l amp
i s i noperati ve.
Refer to Group 8M - Passi ve Restrai nt Systems for
more i nformati on on the ai rbag system.
ANTI-LOCK BRAKE SYSTEM LAMP
The Anti -Lock Brake System (ABS) l amp gi ves an
i ndi cati on when the ABS system i s faul ty or i noper-
ati ve. The l amp i s hard-wi red i n the i nstrument cl us-
ter, and i s compl etel y control l ed by the Control l er
Anti -l ock Brake (CAB). I t recei ves battery vol tage
through the i nstrument cl uster fused i gni ti on swi tch
output feed ci rcui t, and i s grounded by the CAB. The
l amp i s turned on by the CAB for about two seconds
when the i gni ti on swi tch i s turned to the On posi ti on
as a bul b test. After the bul b test, the CAB turns the
l amp on or off based upon the resul ts of the ABS sys-
tem sel f-tests.
The CAB conti nual l y moni tors the ABS ci rcui ts
and sensors to deci de whether the system i s i n good
operati ng condi ti on. I f the CAB turns the l amp on
after the bul b test, i t i ndi cates that the CAB has
detected a system mal functi on and/or that the ABS
system has become i noperati ve. Refer to Group 5 -
Brakes for more i nformati on.
BRAKE WARNING LAMP
The brake warni ng l amp gi ves an i ndi cati on when
the parki ng brake i s appl i ed, or when the pressures
i n the two hal ves of the spl i t brake hydraul i c system
are unequal . The l amp i s turned on by the i nstru-
ment cl uster ci rcui try for about four seconds when
the i gni ti on swi tch i s turned to the On posi ti on as a
bul b test. After the bul b test, the l amp i s control l ed
by the i nstrument cl uster ci rcui try based upon a
message recei ved from the Body Control Modul e
data bus.
The BCM uses i nputs from the parki ng brake
swi tch and the brake warni ng swi tch to deci de
whether the brake warni ng l amp shoul d be on or off.
The BCM then sends the proper message to the
i nstrument cl uster on the CCD data bus to turn the
l amp on or off.
The brake warni ng swi tch cl oses to ground when i t
senses unequal hydraul i c pressures i n the two hal ves
of the spl i t brake hydraul i c system, possi bl y due to
l ow brake fl ui d l evel or brake fl ui d l eakage. The
parki ng brake swi tch cl oses to ground when the
parki ng brake i s appl i ed. Refer to Group 5 - Brakes
CHECK GAUGES LAMP
The check gauges l amp gi ves an i ndi cati on when
certai n gauges refl ect a condi ti on requi ri ng i mmedi -
ate attenti on. The l amp i s turned on by the i nstru-
ment cl uster ci rcui try for about three seconds after
message recei ved from ei ther the Body Control Mod-
ul e (BCM) or the Powertrai n Control Modul e (PCM)
The BCM and PCM use several i nputs to deci de
whether a condi ti on exi sts requi ri ng the check
gauges l amp to be turned on. The responsi bl e modul e
cl uster on the CCD data bus to turn the l amp on or
off. When the i nstrument cl uster ci rcui try recei ves a
check gauges l amp-on message, i t sends a chi me
request message to the BCM on the CCD data bus
for a chi me tone to sound.
The condi ti ons moni tored and the responsi bl e mod-
ul es are:
Engi ne cool ant temperature i s hi gh or cri ti cal
(BCM)
Engi ne oi l pressure i s l ow (BCM)
Chargi ng system fai l ure (PCM)
System vol tage i s hi gh (PCM).
CLUSTER ILLUMINATION LAMP
When the park or head l amps are on, the cl uster
i l l umi nati on l amps l i ght. I l l umi nati on bri ghtness i s
adjusted by sl i di ng the panel di mmer swi tch knob
(downwards to di m, upwards to bri ghten). Each of
the i nstrument cl uster i l l umi nati on l amps recei ves
pul se-wi dth modul ated battery feed from the Body
Control Modul e (BCM) on the hard-wi red panel
l amps dri ver ci rcui t. The BCM moni tors the panel
di mmer resi stor swi tch to determi ne the desi red di m-
mi ng l evel , then adjusts the pul se-wi dth si gnal
accordi ngl y.
The BCM al so sends the proper panel l amps di m-
mi ng l evel message on the Chrysl er Col l i si on Detec-
ti on (CCD) data bus to control the di mmi ng l evel s of
the vari ous vacuum fl uorescent di spl ays. Al l modul es
on the CCD data bus wi th vacuum fl uorescent di s-
pl ays (i nstrument cl uster, radi o, mi ni tri p computer,
vehi cl e i nformati on center) recei ve thi s message and
adjust thei r di mmi ng l evel s to match that of the
i ncandescent cl uster i l l umi nati on bul bs dri ven
di rectl y by the BCM.
Vehi cl es equi pped wi th the automati c headl amps
opti on have an automati c funeral mode or parade
mode. I n thi s mode, the BCM uses an i nput from the
automati c headl amp l i ght sensor to determi ne the
ambi ent l i ght l evel s. I f the BCM deci des that the
exteri or l i ghti ng i s turned on i n the dayl i ght, i t over-
ri des the sel ected panel di mmer swi tch si gnal by
sendi ng a message on the CCD bus to i l l umi nate al l
vacuum fl uorescent di spl ays at ful l bri ghtness for
easi er vi si bi l i ty i n dayti me l i ght l evel s. The auto-
mati c funeral mode or parade mode has no effect on
the i ncandescent bul b di mmi ng l evel s.
Refer to Group 8L - Lamps for more i nformati on.
CRUISE-ON INDICATOR LAMP
The crui se-on i ndi cator l amp gi ves an i ndi cati on
when the vehi cl e speed control system i s turned on,
even when the system i s not currentl y engaged. The
l amp i s turned on by the i nstrument cl uster ci rcui try
for about four seconds when the i gni ti on swi tch i s
the Powertrai n Control Modul e (PCM) on the
The PCM uses an i nput from the anal og resi stor-
mul ti pl exed vehi cl e speed control swi tches i n the
steeri ng wheel to deci de whether to turn the l amp on
or off. The PCM then sends the proper message to
the i nstrument cl uster on the CCD data bus. Refer to
Group 8H - Vehi cl e Speed Control System for more
i nformati on.
HEADLAMP HIGH BEAM INDICATOR LAMP
The headl amp hi gh beam i ndi cator l amp gi ves an
i ndi cati on when the headl amp hi gh beams are turned
on. The l amp i s turned on by the i nstrument cl uster
ci rcui try for about four seconds when the i gni ti on
swi tch i s turned to the On posi ti on as a bul b test.
After the bul b test, the l amp i s control l ed by the
i nstrument cl uster ci rcui try based upon a message
recei ved from the Body Control Modul e (BCM) on the
The BCM uses an i nput from the headl amp di m-
mer (mul ti -functi on) swi tch to deci de whether the
headl amp hi gh beams are turned on. I t then sends
CCD data bus to turn the l amp on or off. Refer to
Group 8L - Lamps for more i nformati on.
LOW FUEL WARNING LAMP
The l ow fuel warni ng l amp gi ves an i ndi cati on
when the fuel l evel i n the fuel tank has fal l en bel ow
about one-ei ghth of a ful l tank, as regi stered on the
fuel gauge. The i nstrument cl uster ci rcui try l i ghts
the l amp for about four seconds when the i gni ti on
After the bul b test, the i nstrument cl uster ci rcui try
control s the l amp based upon a message recei ved
from the Body Control Modul e (BCM) on the
The BCM uses a fuel l evel message recei ved from
the Powertrai n Control Modul e (PCM) on the CCD
data bus to deci de when the fuel l evel i s l ow. The
BCM then sends the proper message to the i nstru-
ment cl uster on the CCD data bus to turn the l amp
on or off. When the l amp-on message i s sent, the
BCM al so i ssues a si ngl e l ow fuel warni ng chi me
tone. Once the l amp i s turned on, an i ncrease i n the
fuel l evel of at l east one-hal f gal l on i s requi red before
the PCM i nput to the BCM wi l l change and cause a
l amp-off message to be i ssued. I f the PCM detects a
short or open i n the fuel gauge sendi ng uni t ci rcui t,
i t sends a message on the CCD data bus that wi l l
cause the fuel gauge poi nter to move to the empty
stop and the l ow fuel l amp to be turned on.
MALFUNCTION INDICATOR LAMP
The Check Engi ne or Mal functi on I ndi cator Lamp
(MI L) gi ves an i ndi cati on when the Powertrai n Con-
trol Modul e (PCM) has recorded a Di agnosti c Troubl e
Code (DTC) for an On-Board Di agnosti cs I I (OBDI I )
emi ssi ons-rel ated ci rcui t or component mal functi on.
The l amp i s turned on by the i nstrument cl uster ci r-
cui try for about three seconds when the i gni ti on
recei ved from the PCM on the Chrysl er Col l i si on
The PCM uses i nputs from many emi ssi ons-rel ated
ci rcui ts and sensors, al ong wi th i ts i nternal program-
mi ng, to deci de whether a condi ti on exi sts that
requi res the MI L l amp to be turned on. The PCM
MI L l amp-on message from the PCM, i t sends a
chi me request message to the Body Control Modul e
(BCM) on the CCD data bus for a si ngl e chi me tone
to sound.
The MI L l amp can al so be used to di spl ay a stored
DTC by fl ashi ng on and off. Refer to Group 14 - Fuel
Systems for more i nformati on on the PCM or the
PCM i nputs. Refer to Group 25 - Emi ssi on Control
Systems for more i nformati on on DTCs and thei r
retri eval .
MASTER LIGHTING INDICATOR LAMP
Vehi cl es sol d i n countri es where i t i s requi red
equi pment, have a master l i ghti ng i ndi cator l amp.
The master l i ghti ng i ndi cator l amp gi ves an i ndi ca-
ti on when the exteri or l amps are l i ghted. The l amp i s
hard-wi red i n the i nstrument cl uster, and i s com-
pl etel y control l ed by the panel l amps dri ver ci rcui t.
The l amp i s grounded at al l ti mes and recei ves a
Control Modul e (BCM). The i nstrument cl uster ci r-
cui try does not perform a bul b test for thi s l amp.
Refer to Cl uster I l l umi nati on Lamp i n thi s group, or
to Group 8L - Lamps for more i nformati on.
SEAT BELT REMINDER LAMP
The seat bel t remi nder l amp gi ves a vi sual
remi nder to the vehi cl e occupants to fasten thei r seat
bel ts. The l amp i s turned on by the i nstrument cl us-
ter ci rcui try for about seven seconds when the i gni -
ti on swi tch i s turned to the On posi ti on. I f the dri ver
seat bel t swi tch i s cl osed (seat bel t i s not buckl ed),
the Body Control Modul e (BCM) wi l l al so sound a
chi me warni ng for the durati on of the seat bel t
remi nder l amp i l l umi nati on. The chi me warni ng wi l l
stop when the dri ver seat bel t swi tch i s open (seat
bel t i s buckl ed).
The seat bel t remi nder l amp al so serves as a
backup for the ai rbag i ndi cator l amp. Fol l owi ng the
seat bel t remi nder l amp seven second di spl ay func-
ti on, i f the i nstrument cl uster ci rcui try has detected
an i noperati ve ai rbag i ndi cator l amp ci rcui t i t wi l l
fl ash the seat bel t remi nder l amp on and off for
twenty seconds. I f the seat bel t remi nder l amp
fl ashes l onger than twenty seconds, or fl ashes at any
ti me other than i mmedi atel y after the i ni ti al seven
second seat bel t remi nder l amp di spl ay, i t i ndi cates
an ai rbag system faul t has been detected and that
the ai rbag i ndi cator l amp i s i noperati ve.
Refer to Group 8U - Chi me/Buzzer Warni ng Sys-
tems for more i nformati on.
TURN SIGNAL INDICATOR LAMP
The l eft and ri ght turn si gnal i ndi cator l amps gi ve
an i ndi cati on when the turn si gnal ci rcui ts are acti -
vated. These l amps are hard-wi red i n the i nstrument
cl uster, and are compl etel y control l ed by the turn si g-
nal and hazard warni ng (mul ti -functi on) swi tches.
The i ndi cator l amps are grounded at al l ti mes and
recei ve battery feed through the contacts of the
mul ti -functi on swi tch when the turn si gnal l ever
(mul ti -functi on swi tch stal k) or hazard warni ng but-
ton are actuated to the On posi ti on. The i nstrument
cl uster ci rcui try does not perform a bul b test of these
l amps. Refer to Group 8J - Turn Si gnal and Hazard
Warni ng Systems for more i nformati on.
UPSHIFT INDICATOR LAMP
Vehi cl es equi pped wi th a manual transmi ssi on
have an upshi ft i ndi cator l amp. The upshi ft i ndi cator
l amp gi ves an i ndi cati on when the dri ver shoul d shi ft
to the next hi ghest gear for the best fuel economy.
The PCM uses i nputs from many sensors and i ts
i nternal programmi ng to deci de whether the engi ne
speed and l oad condi ti ons are proper for a transmi s-
si on upshi ft. The PCM then sends the proper mes-
sage to the i nstrument cl uster on the CCD data bus
to turn the l amp on or off. The PCM wi l l send a
l amp-off message three to fi ve seconds after a
l amp-on message, i f an upshi ft i s not performed. The
l amp wi l l then remai n off unti l the vehi cl e stops
accel erati ng and i s brought back i nto the range of
l amp operati on, or unti l the transmi ssi on i s shi fted
i nto another gear. Refer to Group 14 - Fuel Systems
for more i nformati on on the PCM and the PCM
i nputs.
WAIT-TO-START LAMP
Vehi cl es equi pped wi th an opti onal di esel engi ne
have a wai t-to-start l amp. The wai t-to-start l amp
gi ves an i ndi cati on that the condi ti ons for easi est
starti ng of the di esel engi ne have not yet been
achi eved. The l amp i s turned on by the i nstrument
cl uster ci rcui try for about four seconds when the
i gni ti on swi tch i s turned to the On posi ti on as a bul b
test. After the bul b test, the l amp i s control l ed by the
i nternal programmi ng to determi ne whether the
proper condi ti ons exi st for easi est di esel engi ne start-
i ng. The PCM then sends the proper message to the
l amp on or off. Refer to Group 14 - Fuel Systems for
more i nformati on on the PCM and the PCM i nputs.
WATER-IN-FUEL LAMP
have a water-i n-fuel l amp. The water-i n-fuel l amp
gi ves an i ndi cati on when the water contami nati on i n
the di esel fuel exceeds a certai n l evel . The l amp i s
turned on by the i nstrument cl uster ci rcui try for
about three seconds when the i gni ti on swi tch i s
The PCM uses an i nput from the water-i n-fuel sen-
sor i n the fuel fi l ter/water separator to determi ne
that excess water has accumul ated i n the di esel fuel .
The PCM then sends the proper message to the
more i nformati on.
INSTRUMENT CLUSTER
Al l of the gauges and most of the i ndi cator l amps
i n the i nstrument cl uster are control l ed by messages
recei ved by the i nstrument cl uster ci rcui try on the
CCD data bus. Onl y the cl uster i l l umi nati on l amps,
anti -l ock brake system l amp, turn si gnal i ndi cator
l amps, and the master l i ghti ng i ndi cator l amp (i f the
vehi cl e i s so equi pped) are hard-wi red i n the gauge
cl uster.
I f an i ndi vi dual gauge or l amp i s i noperati ve, see
the di agnosti c procedure under the headi ng for that
gauge or l amp. For ci rcui t descri pti ons and di agrams,
refer to 8W-40 - I nstrument Cl uster i n Group 8W -
Wi ri ng Di agrams. I f more than one gauge or l amp i s
i noperati ve, perform the fol l owi ng:
INJURY.
(1) Check the fuse i n the juncti on bl ock modul e. I f
OK, go to Step 2. I f not OK, repl ace the faul ty fuse.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the i nstrument cl uster bezel and the cl uster
assembl y as descri bed i n thi s group.
(3) Connect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
cl uster wi re harness connector. I f OK, go to Step 4. I f
not OK, repai r the open ci rcui t from the fuse as
requi red.
Probe each ground ci rcui t cavi ty of the cl uster wi re
harness connector. Check for conti nui ty to a good
ground. There shoul d be conti nui ty. I f OK, refer to
the proper Body Di agnosti c Procedures manual for
further testi ng of the i nstrument cl uster ci rcui try
and the CCD data bus wi th a DRB scan tool . I f not
OK, repai r the open ci rcui t to ground as requi red.
I f the probl em bei ng di agnosed i s rel ated to gauge
accuracy, be certai n to confi rm that the probl em i s
wi th the gauge and not wi th cool i ng system perfor-
mance. The actual engi ne cool ant temperature shoul d
be checked wi th a test gauge or thermometer and
compared to the gauge readi ngs before you proceed
wi th gauge di agnosi s. Refer to Group 7 - Cool i ng Sys-
tem for more i nformati on. Refer to Group 8W - Wi r-
i ng Di agrams for ci rcui t descri pti ons and di agrams.
INJURY.
Di agnosi s of the cool ant temperature sensor and
ci rcui t or the Powertrai n Control Modul e (PCM)
shoul d be performed wi th the DRB scan tool as
descri bed i n the proper Powertrai n Di agnosti c Proce-
dures manual . Di agnosi s of the cool ant temperature
gauge, the i nstrument cl uster ci rcui try, or the CCD
data bus shoul d be performed wi th the DRB scan tool
as descri bed i n the proper Body Di agnosti c Proce-
dures manual .
FUEL GAUGE
wi th the gauge or sendi ng uni t and not wi th the fuel
tank. I nspect the fuel tank for si gns of damage or
di storti on that coul d affect the sendi ng uni t perfor-
mance before you proceed wi th gauge di agnosi s.
Refer to Group 8W - Wi ri ng Di agrams for ci rcui t
descri pti ons and di agrams.
INJURY.
Di agnosi s of the fuel gauge sendi ng uni t and ci r-
cui t or the Powertrai n Control Modul e (PCM) shoul d
be performed wi th a DRB scan tool as descri bed i n
the proper Powertrai n Di agnosti c Procedures man-
ual . Di agnosi s of the fuel gauge, the i nstrument cl us-
ter ci rcui try, or the CCD data bus shoul d be
performed wi th the DRB scan tool as descri bed i n the
proper Body Di agnosti c Procedures manual .
wi th the gauge and not wi th an i ncorrect speedome-
ter pi ni on gear, axl e rati o, or ti re si ze. Refer to Group
21 - Transmi ssi on for more i nformati on on the speed-
ometer pi ni on gear. Refer to Group 8W - Wi ri ng Di a-
grams for ci rcui t descri pti ons and di agrams.
INJURY.
Di agnosi s of the vehi cl e speed sensor and ci rcui t or
the Powertrai n Control Modul e (PCM) shoul d be per-
formed wi th the DRB scan tool as descri bed i n the
proper Powertrai n Di agnosti c Procedures manual .
Di agnosi s of the odometer and tri p odometer di spl ay,
the i nstrument cl uster ci rcui try, the Body Control
Modul e (BCM), or the CCD data bus shoul d be per-
OIL PRESSURE GAUGE
wi th the gauge and not wi th the engi ne oi l i ng system
performance. The actual engi ne oi l pressure shoul d
be checked wi th a test gauge and compared to the
i nstrument cl uster gauge readi ngs before you proceed
wi th gauge di agnosi s. Refer to Group 9 - Engi nes for
more i nformati on. Refer to Group 8W - Wi ri ng Di a-
INJURY.
Di agnosi s of the oi l pressure sensor and ci rcui t or
Di agnosi s of the oi l pressure gauge, the i nstrument
cl uster ci rcui try, or the CCD data bus shoul d be per-
SPEEDOMETER
INJURY.
Di agnosi s of the speedometer, the i nstrument cl uster
ci rcui try, or the CCD data bus shoul d be performed
wi th the DRB scan tool as descri bed i n the proper
Body Di agnosti c Procedures manual .
TACHOMETER
INJURY.
descri pti ons and di agrams. Di agnosi s of the crank-
shaft posi ti on sensor and ci rcui t or the Powertrai n
Control Modul e (PCM) shoul d be performed wi th the
DRB scan tool as descri bed i n the proper Powertrai n
Di agnosti c Procedures manual . Di agnosi s of the
tachometer, the i nstrument cl uster ci rcui try, or the
CCD data bus shoul d be performed wi th the DRB
scan tool as descri bed i n the proper Body Di agnosti c
Procedures manual .
VOLTMETER
accuracy, be certai n to confi rm proper chargi ng sys-
tem operati on before consi deri ng gauge repl acement.
mati on. Refer to Group 8W - Wi ri ng Di agrams for ci r-
cui t descri pti ons and di agrams.
INJURY.
Di agnosi s of the system vol tage i nput ci rcui t or the
Powertrai n Control Modul e (PCM) shoul d be per-
Di agnosi s of the vol tmeter gauge, the i nstrument
The di agnosi s found here addresses an i noperati ve
l amp condi ti on. I f the ai rbag i ndi cator l amp stays on
wi th the i gni ti on swi tch i n the On posi ti on, or comes
on and stays on whi l e dri vi ng, refer to Group 8M -
Passi ve Restrai nt Systems for di agnosi s. For ci rcui t
descri pti ons and di agrams, refer to 8W-40 - I nstru-
ment Cl uster, 8W-43 - Ai rbag System, and 8W-45 -
Body Control Modul e i n Group 8W - Wi ri ng Di a-
grams.
INJURY.
The ai rbag i ndi cator l amp has a l amp backup fea-
ture. Fol l owi ng the seat bel t remi nder l amp di spl ay
functi on, i f the i nstrument cl uster ci rcui try has
detected an i noperati ve ai rbag warni ng l amp ci rcui t
i t wi l l fl ash the seat bel t remi nder l amp on and off
for twenty seconds. Once the i nstrument cl uster ci r-
cui try has detected an i noperati ve ai rbag warni ng
l amp ci rcui t, i f a l amp-on message i s recei ved from
the Ai rbag Control Modul e (ACM) on the CCD data
bus, the seatbel t remi nder l amp wi l l fl ash for twel ve
seconds or the durati on of the ai rbag system mal -
functi on, whi chever i s l onger.
I f the ai rbag i ndi cator l amp fai l s to l i ght when the
i gni ti on swi tch i s turned to the On posi ti on, and the
seat bel t remi nder l amp fl ashes fol l owi ng i ts normal
di spl ay functi on (about seven seconds after the i gni -
ti on swi tch i s turned to the On posi ti on), repl ace the
ai rbag i ndi cator l amp bul b wi th a known good uni t.
I f the ai rbag i ndi cator l amp sti l l fai l s to operate,
di agnosi s of the l amp, the i nstrument cl uster ci r-
cui try, the CCD data bus, and the Body Control Mod-
ul e (BCM) shoul d be performed wi th a DRB scan tool
dures manual .
Anti -l ock Brake System (ABS) l amp condi ti on. I f the
ABS l amp stays on wi th the i gni ti on swi tch i n the
On posi ti on, or comes on and stays on whi l e dri vi ng,
refer to Group 5 - Brakes for di agnosi s. I f no ABS
probl em i s found, the fol l owi ng procedure wi l l hel p
l ocate a short or open i n the ABS l amp ci rcui t. For
ci rcui t descri pti ons and di agrams, refer to 8W-40 -
I nstrument Cl uster, and 8W-35 - Al l -Wheel Anti -Lock
Brakes i n Group 8W - Wi ri ng Di agrams.
INJURY.
(1) Check the fuse i n the juncti on bl ock. I f OK, go
to Step 2. I f not OK, repl ace the faul ty fuse.
check for battery vol tage at the fuse i n the juncti on
bl ock. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the i gni ti on swi tch as requi red.
cabl e. Remove the i nstrument cl uster bezel and the
cl uster assembl y.
battery vol tage between the fused i gni ti on swi tch
output ci rcui t and the ABS warni ng l amp dri ver ci r-
cui t cavi ti es of the cl uster wi re harness connector
wi thi n fi ve seconds of turni ng the i gni ti on swi tch to
the On posi ti on. I f OK, repl ace the faul ty bul b. I f not
OK, go to Step 5.
cabl e. Unpl ug the Control l er Anti -l ock Brake (CAB)
wi re harness connector. Check for conti nui ty between
the ABS warni ng l amp dri ver ci rcui t cavi ty of the
cl uster wi re harness connector and a good ground.
There shoul d be no conti nui ty. I f OK, go to Step 6. I f
not OK, repai r the short ci rcui t as requi red.
(6) Check for conti nui ty between the ABS warni ng
l amp dri ver ci rcui t cavi ti es of the cl uster wi re har-
ness connector and the CAB wi re harness connector.
There shoul d be conti nui ty. I f OK, refer to Group 5 -
Brakes for di agnosi s of the CAB. I f not OK, repai r
the open ci rcui t as requi red.
BRAKE WARNING LAMP
brake warni ng l amp condi ti on. I f the brake warni ng
l amp stays on wi th the i gni ti on swi tch i n the On
posi ti on and the parki ng brake rel eased, or comes on
whi l e dri vi ng, refer to Group 5 - Brakes for di agnosi s.
I f no servi ce brake or parki ng brake probl em i s
found, proceed as fol l ows. Refer to 8W-40 - I nstru-
ment Cl uster, 8W-35 - Al l -Wheel Anti -Lock Brakes,
and 8W-45 - Body Control Modul e i n Group 8W -
Wi ri ng Di agrams for ci rcui t descri pti ons and di a-
grams.
INJURY.
I f the brake warni ng l amp fai l s to l i ght duri ng the
bul b test (for about four seconds after the i gni ti on
swi tch i s turned to the On posi ti on), repl ace the bul b
wi th a known good uni t. I f the l amp sti l l fai l s to
l i ght, di agnosi s of the park brake swi tch and ci rcui t,
the brake warni ng swi tch and ci rcui t, the Body Con-
trol Modul e (BCM), the i nstrument cl uster ci rcui try,
or the CCD data bus shoul d be performed wi th a
DRB scan tool as descri bed i n the proper Body Di ag-
nosti c Procedures manual .
CHECK GAUGES LAMP
l amp condi ti on. I f the check gauges l amp stays on
on whi l e dri vi ng wi th no unusual gauge readi ngs evi -
dent, refer to the proper Body Di agnosti c Procedures
manual for di agnosi s. For ci rcui t descri pti ons and
di agrams, refer to 8W-30 - Fuel /I gni ti on Systems,
8W-40 - I nstrument Cl uster, and 8W-45 - Body Con-
trol Modul e i n Group 8W - Wi ri ng Di agrams.
INJURY.
I f the check gauges l amp fai l s to l i ght duri ng the
bul b test (about three seconds after the i gni ti on
swi tch i s turned to the On posi ti on), repl ace the
check gauges l amp bul b wi th a known good uni t. I f
the check gauges l amp sti l l fai l s to operate, di agnosi s
of the l amp, the i nstrument cl uster ci rcui try, the
CCD data bus, and the Body Control Modul e (BCM)
shoul d be performed wi th a DRB scan tool as
descri bed i n the proper Body Di agnosti c Procedures
manual .
cl uster i l l umi nati on l amp condi ti on. I f the probl em
bei ng di agnosed i s rel ated to the di mmi ng l evel of
the cl uster i l l umi nati on l amps, di agnosi s shoul d be
performed wi th a DRB scan tool as descri bed i n the
proper Body Di agnosti c Procedures manual . For ci r-
cui t descri pti ons and di agrams, refer to 8W-40 -
I nstrument Cl uster, 8W-45 - Body Control Modul e,
and/or 8W-50 - Front Li ghti ng i n Group 8W - Wi ri ng
Di agrams.
INJURY.
I f onl y i ndi vi dual cl uster i l l umi nati on l amps are
i noperati ve, repl ace the faul ty bul bs. I f al l of the
cl uster i l l umi nati on l amps are i noperati ve, proceed
as fol l ows.
cabl e. Remove the cl uster bezel and the cl uster
(2) Connect the battery negati ve cabl e and turn
the park l amps on wi th the headl amp swi tch. Adjust
the panel l amp di mmer swi tch knob to i ts hi ghest
l evel (ful l y upwards). Check for vol tage at the panel
l amp dri ver ci rcui t cavi ty of the cl uster wi re harness
connector. I f OK, repl ace the faul ty i nstrument cl us-
ter. I f not OK, go to Step 3.
cabl e. Unpl ug the whi te 24-way Body Control Modul e
(BCM) wi re harness connector. Check for conti nui ty
between the panel l amp dri ver ci rcui t cavi ti es of the
cl uster wi re harness connector and the BCM wi re
harness connector. I f OK, refer to Group 8L - Lamps
for di agnosi s of the headl amp swi tch and/or the
proper Body Di agnosti c Procedures manual for di ag-
nosi s of the BCM. I f not OK, repai r the open ci rcui t
as requi red.
l amp condi ti on. I f the probl em bei ng di agnosed i s an
i naccurate crui se-on i ndi cator l amp, refer to Group
8H - Vehi cl e Speed Control and/or to the proper Pow-
ertrai n Di agnosti c Procedures manual for di agnosi s.
For ci rcui t descri pti ons and di agrams, refer to 8W-33
- Vehi cl e Speed Control and 8W-40 - I nstrument
Cl uster i n Group 8W - Wi ri ng Di agrams.
INJURY.
I f the crui se-on i ndi cator l amp fai l s to l i ght duri ng
the bul b test (about four seconds after the i gni ti on
crui se-on i ndi cator l amp bul b wi th a known good
uni t. I f the crui se-on l amp sti l l fai l s to operate, di ag-
nosi s of the l amp, the i nstrument cl uster ci rcui try,
and the CCD data bus shoul d be performed wi th a
nosti c Procedures manual . Di agnosi s of the speed
control swi tches and ci rcui ts and/or Powertrai n Con-
trol Modul e (PCM) shoul d be performed wi th a DRB
scan tool as descri bed i n the proper Powertrai n Di ag-
I f the probl em bei ng di agnosed i s rel ated to
Graphi c Di spl ay Modul e (GDM) i l l umi nati on, see the
GDM I l l umi nati on di agnosi s bel ow. I f the probl em
bei ng di agnosed i s rel ated to the four-wheel dri ve
di spl ay or four-wheel dri ve message l amps, see the
Four-Wheel Dri ve I ndi cator Lamp di agnosi s bel ow.
Refer to 8W-46 - Message Center i n Group 8W - Wi r-
i ng Di agrams for compl ete ci rcui t descri pti ons and
di agrams.
GDM ILLUMINATION
i l l umi nati on l amp condi ti on. I f the probl em bei ng
di agnosed i s rel ated to the di mmi ng l evel of the i l l u-
mi nati on l amps, di agnosi s shoul d be performed wi th
a DRB scan tool as descri bed i n the proper Body
Di agnosti c Procedures manual .
INJURY.
I f onl y i ndi vi dual i l l umi nati on l amps are i nopera-
ti ve, repl ace the faul ty bul bs. I f al l of the i l l umi na-
ti on l amps are i noperati ve, proceed as fol l ows.
cabl e. Remove the GDM as descri bed i n thi s group.
Unpl ug the GDM wi re harness connector and connect
the battery negati ve cabl e.
(2) Turn the park l amps on wi th the headl amp
swi tch. Adjust the panel l amp di mmer swi tch knob to
i ts hi ghest l evel (ful l y upwards). Check for vol tage at
the panel l amp dri ver ci rcui t cavi ty of the GDM wi re
harness connector. I f OK, repl ace the faul ty GDM. I f
not OK, go to Step 3.
GDM wi re harness connector and the BCM wi re har-
ness connector. I f OK, refer to Group 8L - Lamps for
di agnosi s of the headl amp swi tch and/or the proper
Body Di agnosti c Procedures manual for di agnosi s of
the BCM. I f not OK, repai r the open ci rcui t as
requi red.
FOUR-WHEEL DRIVE INDICATOR LAMP
INJURY.
(1) Unpl ug the wi re harness connector at the
transfer case swi tch. Check for conti nui ty between
the ground ci rcui t cavi ty of the transfer case swi tch
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 as requi red.
(2) Check the transfer case swi tch conti nui ty whi l e
shi fti ng the transfer case shi ft l ever to the proper
posi ti ons. The swi tch conti nui ty shoul d be as shown
i n (Fi g. 1). I f OK, go to Step 3. I f not OK, repl ace the
faul ty swi tch.
Unpl ug the GDM wi re harness connector.
(4) Check the conti nui ty of the ci rcui t for the i ndi -
cator l amp or wheel l amp that i s not functi oni ng
between the GDM wi re harness connector and the
transfer case swi tch wi re harness connector. There
(5) Repl ace the bul b for the i noperati ve i ndi cator
l amp or wheel l amp. Pl ug i n the GDM and transfer
case wi re harness connectors. Connect the battery
negati ve cabl e and check the operati on of the i noper-
ati ve l amp. I f OK, di scard the faul ty bul b. I f not OK,
repl ace the faul ty GDM.
headl amp hi gh beam i ndi cator l amp condi ti on. I f the
probl em bei ng di agnosed i s rel ated to i noperati ve
headl amp hi gh beams, refer to Group 8L - Lamps for
di agnosi s of the headl amp system. For ci rcui t
ment Cl uster i n Group 8W - Wi ri ng Di agrams.
INJURY.
I f the headl amp hi gh beam i ndi cator l amp fai l s to
l i ght duri ng the bul b test (about four seconds after
the i gni ti on swi tch i s turned to the On posi ti on),
repl ace the headl amp hi gh beam i ndi cator l amp bul b
wi th a known good uni t. I f the i ndi cator l amp sti l l
fai l s to operate, di agnosi s of the l amp, the i nstru-
ment cl uster ci rcui try, the CCD data bus, or the Body
Control Modul e (BCM) shoul d be performed wi th a
Fig. 1 Transfer Case Switch
GROUND #1 100 WAY 231 TRANSFER CASE (COM- MAND-TRAC) T/C POSITION SWITCH POSI- TION
242 TRANSFER CASE
(SELEC-TRAC)
T/C POSITION SWITCH POSI- TION 249 TRANSFER CASE (QUADRA-TRAC) T/C POSITION SWITCH POSITION
2 WD
4 PART TIME
N
4 LO
2WD
4 PART TIME
4 FULL TIME
N
4 LO
4 ALL TIME
N
4 LO
l ow fuel warni ng l amp condi ti on. I f the probl em
bei ng di agnosed i s rel ated to l amp accuracy, be cer-
tai n to confi rm the probl em i s the wi th the l ow fuel
warni ng l amp and not wi th the fuel gauge ci rcui t.
See the di agnosi s for the Fuel Gauge i n thi s group. I f
no fuel gauge probl em i s found, the fol l owi ng proce-
dure wi l l hel p to i denti fy a faul ty l ow fuel warni ng
l amp ci rcui t. For ci rcui t descri pti ons and di agrams,
Wi ri ng Di agrams.
INJURY.
I f the l ow fuel warni ng l amp fai l s to l i ght duri ng
swi tch i s turned to the On posi ti on), repl ace the l ow
fuel warni ng l amp bul b wi th a known good uni t. I f
the i ndi cator l amp sti l l fai l s to operate, di agnosi s of
the l amp, the i nstrument cl uster ci rcui try, the CCD
data bus, or the Body Control Modul e (BCM) shoul d
the proper Body Di agnosti c Procedures manual .
Di agnosi s of the fuel gauge sendi ng uni t and ci rcui t
or the Powertrai n Control Modul e (PCM) shoul d be
mal functi on i ndi cator (Check Engi ne) l amp condi ti on.
I f the l amp comes on and stays on wi th the engi ne
runni ng, refer to Group 14 - Fuel Systems for di ag-
nosi s. For ci rcui t descri pti ons and di agrams, refer to
8W-40 - I nstrument Cl uster i n Group 8W - Wi ri ng
Di agrams.
INJURY.
I f the mal functi on i ndi cator l amp fai l s to l i ght dur-
i ng the bul b test (about three seconds after the i gni -
mal functi on i ndi cator l amp bul b wi th a known good
uni t. I f the i ndi cator l amp sti l l fai l s to operate, di ag-
nosi s of the l amp, the i nstrument cl uster ci rcui try, or
the CCD data bus shoul d be performed wi th a DRB
Procedures manual . Di agnosi s of the Powertrai n Con-
The master l i ghti ng i ndi cator shares the same ci r-
cui try as the cl uster i l l umi nati on l amps, and wi l l
bri ghten and di m when the panel l amp di mmer
swi tch i s adjusted. The di agnosi s found here
addresses an i noperati ve master l i ghti ng i ndi cator
l amp condi ti on. I f the probl em bei ng di agnosed i s
rel ated to the di mmi ng l evel of the master l i ghti ng
i ndi cator l amp, di agnosi s shoul d be performed wi th a
nosti c Procedures manual . For ci rcui t descri pti ons
and di agrams, refer to 8W-40 - I nstrument Cl uster,
8W-45 - Body Control Modul e, and/or 8W-50 - Front
Li ghti ng i n Group 8W - Wi ri ng Di agrams.
INJURY.
I f onl y the master l i ghti ng i ndi cator l amp i s i nop-
erati ve, repl ace the faul ty bul b. I f al l of the cl uster
i l l umi nati on l amps are i noperati ve, proceed as fol -
l ows.
as requi red.
seat bel t remi nder l amp condi ti on. I f the l amp comes
on and fl ashes fol l owi ng i ts di spl ay functi on (for
about seven seconds after the i gni ti on swi tch i s
turned to the On posi ti on), refer to the di agnosi s for
the ai rbag i ndi cator l amp i n thi s group. For ci rcui t
INJURY.
I f the seat bel t remi nder l amp fai l s to l i ght duri ng
i ts di spl ay functi on, repl ace the seat bel t remi nder
l amp bul b wi th a known good uni t. I f the remi nder
l amp sti l l fai l s to operate, di agnosi s of the l amp, and
the i nstrument cl uster ci rcui try shoul d be performed
wi th a DRB scan tool as descri bed i n the proper Body
turn si gnal i ndi cator l amp condi ti on. For any other
turn si gnal probl em, refer to Group 8J - Turn Si gnal
and Hazard Warni ng Systems for di agnosi s. I f no
turn si gnal or hazard warni ng system probl em i s
found, the fol l owi ng procedure wi l l hel p l ocate a
short or open i n the i ndi cator l amp ci rcui t. For ci r-
I nstrument Cl uster and 8W-50 - Front Li ghti ng i n
Group 8W - Wi ri ng Di agrams.
INJURY.
cl uster assembl y as descri bed i n thi s group.
(2) Connect the battery negati ve cabl e. Acti vate
the hazard warni ng system by depressi ng the hazard
warni ng swi tch. Check for battery vol tage at the
i noperati ve (ri ght or l eft) turn si gnal i ndi cator l amp
ci rcui t cavi ty of the cl uster wi re harness connector.
There shoul d be a swi tchi ng (on and off) battery vol t-
age si gnal . I f OK, repl ace the faul ty (ri ght or l eft)
i ndi cator bul b. I f not OK, repai r the open ci rcui t to
the turn si gnal (mul ti -functi on) swi tch as requi red.
upshi ft i ndi cator l amp condi ti on. I f l amp accuracy i s
suspect, di agnosi s shoul d be performed wi th a DRB
and di agrams, refer to 8W-40 - I nstrument Cl uster i n
INJURY.
I f the upshi ft i ndi cator l amp fai l s to l i ght duri ng
the bul b test (about three seconds after the i gni ti on
upshi ft i ndi cator l amp bul b wi th a known good uni t.
I f the i ndi cator l amp sti l l fai l s to operate, di agnosi s
of the l amp, the i nstrument cl uster ci rcui try, or the
CCD data bus shoul d be performed wi th a DRB scan
tool as descri bed i n the proper Body Di agnosti c Pro-
cedures manual . Di agnosi s of the Powertrai n Control
Modul e (PCM) shoul d be performed wi th a DRB scan
tool as descri bed i n the proper Powertrai n Di agnosti c
Procedures manual .
The Vehi cl e I nformati on Center (VI C) has a num-
ber of di spl ay functi ons and features. The di agnosi s
found here addresses onl y those VI C messages and
functi ons that are control l ed by hard-wi red i nputs. To
di agnose any i nternal l y control l ed VI C functi on or
feature, or any that are enabl ed by i nputs on the
CCD data bus network, use a DRB scan tool and the
proper Body Di agnosti c Procedures manual . Refer to
8W-46 - Message Center i n Group 8W - Wi ri ng Di a-
grams for compl ete ci rcui t descri pti ons and di agrams.
COOLANT LEVEL LOW/COOLANT SENSOR
BAD
I f the probl em bei ng di agnosed i s rel ated to l amp
wi th the l amp and sensor and not wi th the engi ne
cool ant l evel . The actual engi ne cool ant l evel shoul d
be checked before you proceed wi th l amp and sensor
di agnosi s. Refer to 8W-46 - Message Center i n Group
8W - Wi ri ng Di agrams for compl ete ci rcui t descri p-
ti ons and di agrams.
INJURY.
(1) Unpl ug the cool ant l evel sensor wi re harness
connector on the cool ant reserve bottl e. Check for
conti nui ty between the ground ci rcui t cavi ty of the
(2) Wi th the engi ne cool ant at the proper l evel ,
check the resi stance between the two termi nal s of
the cool ant l evel sensor. The resi stance shoul d be
3000 to 3500 ohms. I f OK, go to Step 3. I f not OK,
repl ace the faul ty sensor.
cabl e. Remove the VI C modul e as descri bed i n thi s
group. Unpl ug the VI C modul e wi re harness connec-
tor. Check for conti nui ty between the engi ne cool ant
l evel swi tch sense ci rcui t cavi ty of the VI C wi re har-
ness connector and a good ground. There shoul d be
no conti nui ty. I f OK, go to Step 4. I f not OK, repai r
the short ci rcui t as requi red.
(4) Check for conti nui ty between the engi ne cool -
ant l evel swi tch sense ci rcui t cavi ti es of the VI C wi re
harness connector and the engi ne cool ant l evel sensor
wi re harness connector. I f OK, repl ace the faul ty VI C
modul e. I f not OK, repai r the open ci rcui t as
requi red.
FOUR-WHEEL DRIVE DISPLAY AND
INDICATORS/SERVICE 4WD SWITCH
I f the probl em bei ng di agnosed i s rel ated to an
i ncorrect or no four-wheel dri ve di spl ay or i ndi cator
functi ons, be certai n to confi rm that the probl em i s
wi th the VI C modul e and transfer case swi tch ci r-
cui ts, and not wi th a Powertrai n Control Modul e
(PCM) wi th an i ncorrect Vehi cl e I denti fi cati on Num-
ber (VI N). Thi s condi ti on can onl y occur i f the ori gi -
nal PCM was repl aced wi th a uni t from another
vehi cl e. The VI C modul e uses the VI N message
recei ved on the CCD data bus from the PCM to
determi ne i f the vehi cl e i s equi pped wi th two-wheel
dri ve or four-wheel dri ve.
I f a four-wheel dri ve vehi cl e has a two-wheel dri ve
VI N entered i n the PCM, the VI C wi l l i gnore al l
transfer case swi tch i nputs. I f a two-wheel dri ve
vehi cl e has a four-wheel dri ve VI N entered i n the
PCM, the rear wheel s i n the VI C di spl ay wi l l not
l i ght. Use a DRB scan tool and the proper Power-
trai n Di agnosti c Procedures manual to confi rm the
VI N i n the PCM.
I n addi ti on, i t shoul d be noted that a VI C Servi ce
4WD Swi tch message on a two-wheel dri ve vehi cl e
can occur i f a short ci rcui t occurs i n the transfer case
swi tch ci rcui ts from the VI C modul e, i n combi nati on
wi th a PCM havi ng a four-wheel dri ve VI N. To l ocate
the short ci rcui t, start at Step 3 of the fol l owi ng di ag-
nosti c procedure. Two-wheel dri ve model s do have
the same VI C wi re harness provi si ons as four-wheel
dri ve model s.
INJURY.
faul ty swi tch.
tor.
(4) Locate two pai rs of wi re harness connectors
l ocated i n the wi re harness l eadi ng to the VI C mod-
ul e. The wi re harness connectors shoul d be taped
back to the harness. One pai r of connectors are bl ack
wi th a si ngl e cavi ty. The other pai r are red wi th two
cavi ti es. I f the vehi cl e has the Quadra-Trac 4WD
transfer case, onl y the red wi re harness connectors
shoul d be joi ned. I f the vehi cl e has the Command-
Trac or Sel ec-Trac 4WD transfer case, onl y the bl ack
wi re harness connectors shoul d be joi ned. I n al l
cases, onl y one pai r of wi re harness connectors
shoul d be joi ned. I f OK, go to Step 5. I f not OK, cor-
rect the wi re harness connecti ons as requi red.
(5) Refer to the VI C 4WD Di spl ay Characteri sti cs
chart (Fi g. 3). Check the conti nui ty of the ci rcui t for
the i ndi cator l amp or wheel l amp that i s not func-
ti oni ng between the VI C modul e wi re harness con-
nector and the transfer case swi tch wi re harness
connector. There shoul d be conti nui ty. I f OK, repl ace
the faul ty VI C modul e. I f not OK, repai r the open ci r-
cui t as requi red.
REAR LAMP FAILURE
Refer to the di agnosi s for the l amp outage modul e
i n Group 8L - Lamps to di agnose thi s feature of the
VI C modul e. Refer to 8W-46 - Message Center i n
Group 8W - Wi ri ng Di agrams for compl ete ci rcui t
TURN SIGNAL ON
Refer to Group 8J - Turn Si gnal and Hazard Warn-
i ng Systems for more i nformati on on thi s feature of
the VI C modul e. The VI C modul e uses i ts i nternal
programmi ng, and i nputs from the combi nati on
fl asher on the fused i gni ti on swi tch output (L5) ci r-
cui t, and a vehi cl e speed sensor (di stance) message
recei ved on the CCD data bus from the Powertrai n
Control Modul e to control thi s message.
I f testi ng of the L5 ci rcui t between the VI C modul e
wi re harness connector and the combi nati on fl asher
cavi ty i n the juncti on bl ock reveal s no probl em, use a
DRB scan tool and the proper Body Di agnosti c Pro-
cedures manual to di agnose the VI C modul e and the
CCD data bus. Refer to 8W-46 - Message Center i n
WASHER LEVEL LOW/WASHER SENSOR BAD
wi th the l amp and sensor and not wi th the washer
fl ui d l evel . The actual fl ui d l evel shoul d be checked
before you proceed wi th l amp and sensor di agnosi s.
di agrams.
GROUND #1 100 WAY 231 TRANSFER CASE (COM- MAND-TRAC) T/C POSITION SWITCH POSI- TION
242 TRANSFER CASE
(SELEC-TRAC)
T/C POSITION SWITCH POSI- TION 249 TRANSFER CASE (QUADRA-TRAC) T/C POSITION SWITCH POSITION
2 WD
4 PART TIME
N
4 LO
2WD
4 PART TIME
4 FULL TIME
N
4 LO
4 ALL TIME
N
4 LO
INJURY.
(1) Unpl ug the washer fl ui d l evel sensor wi re har-
ness connector on the washer reservoi r bottl e. Check
for conti nui ty between the ground ci rcui t cavi ty of
the wi re harness connector and a good ground. There
(2) Wi th the washer fl ui d at the proper l evel ,
the washer fl ui d l evel sensor. The resi stance shoul d
be 3000 to 3500 ohms. I f OK, go to Step 3. I f not OK,
tor. Check for conti nui ty between the washer fl ui d
l evel sense ci rcui t cavi ty of the VI C modul e wi re har-
(4) Check for conti nui ty between the washer fl ui d
l evel sense ci rcui t cavi ti es of the VI C modul e wi re
harness connector and the washer fl ui d l evel sensor
requi red.
WAIT-TO-START LAMP
wai t-to-start l amp condi ti on. I f l amp accuracy i s sus-
pect, di agnosi s shoul d be performed wi th a DRB scan
Procedures manual . For ci rcui t descri pti ons and di a-
grams, refer to 8W-40 - I nstrument Cl uster i n Group
INJURY.
I f the wai t-to-start l amp fai l s to l i ght duri ng the
bul b test (about four seconds after the i gni ti on swi tch
i s turned to the On posi ti on), repl ace the wai t-to-
start l amp bul b wi th a known good uni t. I f the l amp
sti l l fai l s to operate, di agnosi s of the l amp, the
i nstrument cl uster ci rcui try, or the CCD data bus
manual . Di agnosi s of the Powertrai n Control Modul e
(PCM) shoul d be performed wi th a DRB scan tool as
dures manual .
WATER-IN-FUEL LAMP
water-i n-fuel l amp condi ti on. I f the l amp comes on
and stays on wi th the i gni ti on swi tch i n the On posi -
ti on or whi l e dri vi ng, be certai n to check for excess
DRIVE SYSTEM
(TRANSFER CASE)
VIC 4WD DIS-
PLAY CHARAC-
TERISTICS
TRANSFER CASE SHIFT LEVER POSITION
2WD
4 PART
TIME
4 FULL
/ALL
TIME
NEUTRAL 4 LO
4WD QUADRA-TRAC
(NP249)
Nomenclature N/A N/A None None LO
Lighted Wheels N/A N/A All None All
4WD SELEC-TRAC
(NP242)
Nomenclature None PART
TIME
FULL
TIME
None PART TIME
Lighted Wheels Rear All All None All
4WD COMMAND-TRAC
(NP231)
Nomenclature None PART
TIME
N/A None PART TIME
Lighted Wheels Rear All N/A None All
2WD
(NONE)
Nomencalture None N/A N/A N/A N/A
Lighted Wheels None N/A N/A N/A N/A
Fig. 3 VIC 4WD Display Characteristics
water accumul ati on i n the fuel fi l ter/water separator
before attempti ng further di agnosi s. Refer to Group
14 - Fuel Systems for di agnosi s and servi ce of the
water-i n-fuel sensor. For ci rcui t descri pti ons and di a-
INJURY.
I f the water-i n-fuel l amp fai l s to l i ght duri ng the
water-i n-fuel l amp bul b wi th a known good uni t. I f
the l amp, the i nstrument cl uster ci rcui try, or the
Procedures manual .
SERVICE PROCEDURES
The fol l owi ng fl ow charts descri be the procedures
to perform an i ni ti al setup of the Vehi cl e I nformati on
Center (VI C), and how to reset the VI C servi ce
remi nder or ti me/date setti ngs.
I f the vehi cl e i s equi pped wi th a Chrysl er radi o
that i s connected to the Chrysl er Col l i si on Detecti on
(CCD) data bus network, the hour and mi nute set-
ti ngs of the VI C cl ock wi l l automati cal l y be synchro-
ni zed to the hour and mi nute setti ngs of the radi o
cl ock. Thi s i s done by a message that the radi o sends
to the VI C modul e on the CCD data bus. Al so, the
VI C modul e wi l l automati cal l y suppress the VI C
hour and mi nute set functi ons i f there i s a Chrysl er
radi o connected to the CCD data bus, and the VI C
cl ock must be set through the radi o cl ock. Refer to
Group 8F - Audi o Systems for more i nformati on on
thi s feature.
VIC Initial Setup
TO PERFORM VIC INITIAL SET-UP, PROCEED AS FOL- LOWS. **DEPRESS AND HOLD VIC SET BUTTON WHILE TURNING IGNITION SWITCH TO ON. RELEASE SET BUTTON. DONE VIC DISPLAYS CURRENT LANGUAGE SETTING. AVAILABLE LANGUAGES ARE: ENGLISH, FRENCH, GERMAN, SPANISH, AND ITALIAN. DEPRESS AND RELEASE THE SELECT BUTTON TO TOGGLE THROUGH THE AVAILABLE CHOICES UNTIL THE DESIRED LANGUAGE SETTING IS DISPLAYED. DONE DEPRESS AND RELEASE THE SET BUTTON TO CHOOSE THE DIS- PLAYED LANGUAGE SETTING AND ADVANCE TO THE NEXT VIC SET-UP. DONE DEPRESS AND RELEASE THE SET BUTTON TO CHOOSE THE DIS- PLAYED CLOCK MODE SETTING, AND ADVANCE TO THE NEXT VIC SET-UP. DONE DEPRESS AND RELEASE THE SELECT BUT- TON TO TOGGLE BETWEEN THE AVAIL- ABLE CLOCK MODES UNTIL THE DESIRED CLOCK MODE SET- TING IS DIS- PLAYED. VIC DISPLAYS CURRENT CLOCK MODE SETTING. AVAILABLE CLOCK MODES ARE: 12 HOUR CLOCK, AND 24 HOUR CLOCK. *VIC DIS- PLAYS CUR- RENT SER- VICE INTERVAL SET- TING. AVAIL- ABLE INTER- VALS ARE: FROM 7500 TO 2000 MILES IN 500 MILE INCRE- MENTS, OR FROM 12,000 TO 3000 KMS IN 1000 KM INCRE- MENTS. DEPRESS AND RELEASE THE SELECT BUTTON TO TOGGLE THROUGH THE AVAILABLE SRVICE INTERVALS UNTIL THE DESIRED SERVICE INTERVAL SETTING IS DIS- PLAYED. DONE DEPRESS AND RELEASE THE SET BUTTON TO CHOOSE THE DIS- PLAYED SER- VICE INTERVAL SET- TING AND STORE ALL SET- TINGS IN VIC MEMORY. DONE DONE **NOTE: TURNING IGNITION SWITCH TO OFF BEFORE ENTIRE SET-UP PROCE- DURE IS COMPLETE ABORTS VIC SET-UP NOTH- ING IS SAVED. END OF VIC SET-UP PROCEDURE. *NONE: VIC DISPLAY DURING SET-UP WILL REFLECT MILES OR KILOMETERS AS SELECTED WITH THE US/METRIC BUTTON IN THE OVERHEAD CONSOLE BEFORE THE SET-UP PROCEDURE WAS BEGUN.
VIC Reset
TO RESET VIC SERVICE REMINDER FEATURE AFTER RECOMMENDED SERVICE HAS BEEN PERFORMED, PROCEED AS FOLLOWS.
SWITCH POD BEZEL
INJURY.
Both swi tch pod bezel s are secured to the i nstru-
ment panel wi th spri ng cl i p retai ners and a l i ght
snap fi t. To remove the bezel from the i nstrument
panel , pry gentl y around the edges of the bezel usi ng
a tri m sti ck or other sui tabl e wi de fl at-bl aded tool . To
i nstal l the bezel , hol d i t i n posi ti on wi th one hand,
then push the bezel fi rml y i nto pl ace wi th the other
hand.
KNEE BLOCKER
INJURY.
cabl e.
(2) Remove both swi tch pod bezel s as descri bed i n
thi s group.
(3) Remove one screw on each si de of the steeri ng
col umn that secures the upper edge of the knee
bl ocker/steeri ng col umn cover to the i nstrument
panel (Fi g. 4).
(4) Remove the one screw that secures the out-
board end of the knee bl ocker to the i nstrument
panel .
(5) Remove the four screws that secure the l ower
edge of the knee bl ocker to the l ower i nstrument
panel rei nforcement.
(6) Usi ng a tri m sti ck or other sui tabl e wi de fl at-
bl aded tool , gentl y pry the edges of the knee bl ocker
away from the i nstrument panel at the snap cl i p
retai ner l ocati ons (Fi g. 4).
(7) Remove the knee bl ocker/steeri ng col umn cover
from the vehi cl e.
CLUSTER BEZEL
INJURY.
cabl e.
thi s group.
(3) Remove the ten screws that secure the cl uster
bezel to the i nstrument panel (Fi g. 5).
(4) Pul l the cl uster bezel rearward and move i t to
the outboard si de of the steeri ng wheel to remove i t
from the vehi cl e.
Fig. 4 Knee Blocker Remove/Install
SNAP CLIP LOCA- TIONS INBOARD SWITCH POD BEZEL KNEE BLOCKER SCREW OUTBOARD SWITCH POD BEZEL
Fig. 5 Cluster Bezel Screws Remove/Install
CLUSTER BEZEL SCREWS 8E - 24 INSTRUMENT PANEL SYSTEMS ZG
INSTRUMENT CLUSTER
INJURY.
(1) Remove the cl uster bezel as descri bed i n thi s
group.
(2) Remove the two screws that secure each end of
the i nstrument cl uster to the i nstrument panel .
(3) Pul l the i nstrument cl uster rearward and
remove i t from the vehi cl e.
CLUSTER LENS, HOOD, AND MASK
INJURY.
group.
(2) Remove the i nstrument cl uster as descri bed i n
thi s group.
(3) Remove the tri p odometer reset knob by pul l i ng
i t off of the swi tch stem (Fi g. 6).
(4) Depress the snap cl i ps that secure the cl uster
l ens to the cl uster hood and gentl y pul l the l ens
away from the hood.
hood to the cl uster ci rcui t and gauge housi ng and
gentl y pul l the hood away from the housi ng.
(6) Gentl y l i ft the gauge mask away from the
l ocati ng pi ns on the front of the cl uster ci rcui t and
gauge housi ng.
Fig. 6 Instrument Cluster Components
REAR HOUSING COVER CLUSTER CIRCUIT AND GAUGE HOUSING MASK HOOD LENS TRIP ODOMETER RESET KNOB
GAUGE
INJURY.
(1) Remove the cl uster l ens, hood, and mask as
descri bed i n thi s group.
(2) Remove the screws that secure the gauge(s)
from the rear of the cl uster ci rcui t and gauge housi ng
(Fi g. 7).
(3) Remove the gauge(s) from the front of the cl us-
ter ci rcui t and gauge housi ng.
CLUSTER BULB
INJURY.
thi s group.
(2) Remove the bul b and hol der from the rear of
the cl uster housi ng by turni ng the hol der counter-
cl ockwi se (Fi g. 8).
(3) Unpl ug the bul b from the hol der.
CAUTION: Always use the correct bulb size and
type for replacement. An incorrect bulb size or type
may overheat and cause damage to the instrument
cluster printed circuit and/or the gauges.
OUTBOARD SWITCH POD
INJURY.
group.
(2) Remove the two screws that secure the out-
board swi tch pod to the i nstrument panel (Fi g. 9).
(3) Pul l the outboard swi tch pod out from the
i nstrument panel far enough to unpl ug the wi re har-
ness connectors.
Fig. 7 Gauge Mounting Screws
GAUGE MOUNTING SCREWS GAUGE MOUNTING SCREWS
(4) Remove the outboard swi tch pod from the
i nstrument panel .
INBOARD SWITCH POD
INJURY.
cabl e.
(2) Remove the i nboard swi tch pod bezel as
(3) Remove the two screws that secure the i nboard
swi tch pod to the i nstrument panel (Fi g. 10).
(4) Pul l the i nboard swi tch pod out from the
ness connectors.
(5) Remove the i nboard swi tch pod from the
i nstrument panel .
Fig. 8 Cluster Bulb Locations
CLUSTER ILLUMINATION LAMPS TURN SIGNAL INDICATOR LAMPS INDICATOR LAMPS
Fig. 9 Outboard Switch Pod Remove/Install
OUTBOARD SWITCH POD MOUNTING SCREWS
Fig. 10 Inboard Switch Pod Remove/Install
INBOARD SWITCH POD MOUNT- ING SCREWS
BODY CONTROL MODULE
INJURY.
as descri bed i n thi s group.
(2) Remove the four screws bel ow the outboard
swi tch pod that secure the Body Control Modul e
(BCM) to the i nstrument panel armature (Fi g. 11).
(3) Move the BCM towards the steeri ng col umn far
enough to unpl ug the three wi re harness connectors.
(4) Remove the BCM from the i nstrument panel .
NOTE: If a new Body Control Module is installed,
the programmable features must be enabled and/or
disabled to the customers preferred settings. Use a
DRB scan tool and the proper Body Diagnostic Pro-
cedures manual to perform these operations.
GLOVE BOX MODULE
INJURY.
(2) Remove the two screws that secure the top of
the i nstrument panel center bezel to the i nstrument
panel above the Graphi c Di spl ay Modul e (GDM) or
Vehi cl e I nformati on Center (VI C).
(3) Remove the ash recei ver from the i nstrument
panel center bezel .
(4) Remove the two screws i n the back of the ash
recei ver openi ng that secure the i nstrument panel
center bezel to the i nstrument panel armature.
(5) Remove the screw that secures the courtesy
l amp l ocated under the outboard end of the gl ove box
modul e.
(6) Open the passenger si de front door and remove
the screw that secures the outboard end of the gl ove
box modul e.
(7) Remove the four screws that secure the gl ove
box hi nge to the i nstrument panel armature on the
l ower edge of the gl ove box modul e.
(8) Open the gl ove box door and remove the four
screws at the top of the gl ove box openi ng that secure
the upper edge of the gl ove box modul e to the i nstru-
ment panel armature.
(9) Lower the gl ove box modul e far enough to
unpl ug the wi re harness connectors from the gl ove
box l amp and swi tch, the ci gar l i ghter and l amp, and
the power outl et. Al so remove the ash recei ver l amp
bul b and socket as a uni t by gentl y pul l i ng i t out of
the ash recei ver l amp hood.
(10) Remove the gl ove box modul e from the vehi -
cl e.
INFORMATION CENTER
INJURY.
(1) Remove the gl ove box modul e as descri bed i n
thi s group.
Fig. 11 Body Control Module Remove/Install
OUTBOARD SWITCH POD BODY CONTROL MODULE MOUNTING SCREWS DATA LINK CON- NECTOR INSTRUMENT PANEL ARMA- TURE
(2) Remove the three screws that secure the
Graphi c Di spl ay Modul e (GDM) or Vehi cl e I nforma-
ti on Center (VI C) to the i nstrument panel armature
(Fi g. 12).
(3) Pul l the GDM or VI C uni t out from the i nstru-
ment panel far enough to unpl ug the wi re harness
connector.
(4) Remove the GDM or VI C from the i nstrument
panel .
GLOVE BOX LAMP AND SWITCH
INJURY.
thi s group.
(2) From the back si de of the gl ove box modul e,
squeeze the retai ni ng tabs on the gl ove box l amp and
swi tch housi ng together and push the uni t out the
front of the modul e through the mounti ng hol e (Fi g.
13).
(3) To i nstal l the gl ove box l amp and swi tch uni t,
i nsert the uni t through the mounti ng hol e from the
front of the gl ove box modul e and push i n on the uni t
fi rml y, unti l the retai ni ng tabs snap i nto pl ace.
(4) Reverse the remai ni ng removal procedures to
compl ete the i nstal l ati on.
GLOVE BOX LATCH STRIKER
INJURY.
thi s group.
(2) From the top of the gl ove box modul e,
strai ghten the two mounti ng tabs that secure the
stri ker to the modul e (Fi g. 14).
(3) Pul l the l atch stri ker out from the upper gl ove
box openi ng.
(4) To i nstal l the l atch stri ker, i nsert the mounti ng
tabs through the sl ots i n the upper gl ove box openi ng
and bend the tabs over from the top of the gl ove box
modul e.
Fig. 12 Graphic Display Module and Vehicle
Information Center Remove/Install
MOUNTINGSCREWS
Fig. 13 Glove Box Lamp and Switch Remove/Install
GLOVE BOX MOD- ULE GLOVE BOX LAMP AND SWITCH
Fig. 14 Glove Box Latch Striker Remove/Install
MOUNTING TABS LATCH STRIKER GLOVE BOX MODULE
CIGAR LIGHTER
INJURY.
cabl e.
(2) Pul l the ci gar l i ghter knob and el ement out of
the ci gar l i ghter base.
(3) Look i nsi de the ci gar l i ghter base and note the
posi ti on of the retai ni ng bosses that secure the uni t
to the l i ght ri ng/retai ner i n the i nstrument panel
center bezel (Fi g. 15).
(4) I nsert a pai r of external snap ri ng pl i ers i nto
the ci gar l i ghter base and engage the ti ps of the pl i -
ers wi th the retai ni ng bosses.
(5) Squeeze the pl i ers to di sengage the retai ni ng
bosses from the base, and usi ng a gentl e rocki ng
moti on pul l the pl i ers and the ci gar l i ghter base out
of the l i ght ri ng/retai ner.
(6) Remove the pl i ers from the ci gar l i ghter base
and unpl ug the wi re harness connector.
(7) Remove the ci gar l i ghter l i ght ri ng/retai ner
from the i nstrument panel center bezel and unpl ug
the wi re harness connector.
POWER OUTLET
INJURY.
thi s group.
(2) From the rear of the i nstrument panel center
bezel , unscrew the power outl et shel l cl amp from the
power outl et base.
(3) Remove the power outl et base from the front of
the i nstrument panel center bezel .
POWER OUTLET DOOR
(1) I nsert a wi de fl at-bl aded tool such as a tri m
sti ck between the si de of the power outl et housi ng i n
the i nstrument panel center bezel and the upper
pi vot area of the power outl et door.
(2) Pry gentl y agai nst the upper pi vot area of the
power outl et door unti l the door pi vot pi n cl ears the
pi vot receptacl e i n the i nstrument panel center bezel .
(3) Pul l the power outl et door out of the power out-
l et housi ng.
(4) To i nstal l the door, i nsert one of the pi vot pi ns
i nto a pi vot receptacl e i n the center bezel and twi st
the door gentl y unti l the pi vot pi n on the opposi te
si de of the door snaps i nto the other pi vot receptacl e.
INSTRUMENT PANEL CENTER BEZEL
INJURY.
thi s group.
(2) Remove the two screws that secure the i nstru-
ment panel center bezel to the i nboard end of the
gl ove box modul e from the back si de of the gl ove box
modul e (Fi g. 16).
Fig. 15 Cigar Lighter Remove/Install
KNOB ELE- MENT RETAINING BOSSES-ENGAGE PLI- ERS HERE PARTIALLY REMOVED EXTERNAL SNAP- RING PLIERS PULL BASE OUT-THROUGH LIGHT RING
GLOVE BOX
INJURY.
cabl e.
(2) Dri l l out the two ri vets that secure the gl ove
box hi nge to the l ower edge of the gl ove box modul e
(Fi g. 17).
NOTE: The rivets are used to ease assembly during
the manufacturing process, but do not require
replacement following service.
box hi nge to the i nstrument panel armature.
(4) Rel ease the gl ove box l atch and remove the
gl ove box from the gl ove box modul e.
GLOVE BOX COMPONENTS
The gl ove box bezel i s the onl y component of the
gl ove box that can be servi ced wi thout gl ove box
removal . Al l other components wi l l requi re that the
gl ove box be removed from the gl ove box modul e as
GLOVE BOX BEZEL
(1) Open the gl ove box.
(2) Remove the two screws that secure the bezel at
the top of the gl ove box i nner door panel (Fi g. 18).
(3) Careful l y pry the bezel away from the outsi de
of the gl ove box door. There i s doubl e-faced adhesi ve
tape between the bezel and the outer door panel .
GLOVE BOX HINGE
(1) Remove the gl ove box as descri bed i n thi s
group.
(2) Remove the screws that secure the gl ove box
hi nge to the gl ove box i nner door panel .
(3) Remove the gl ove box hi nge.
GLOVE BOX BIN
group.
(2) Remove the gl ove box hi nge as descri bed i n
thi s group.
(3) Remove the screws that secure each si de of the
bi n to the gl ove box door.
(4) Remove the gl ove box bi n.
Fig. 16 Instrument Panel Center Bezel Remove/
Install
SCREWCENTER BEZEL UPPER MOUNTING HOLES GLOVE BOX MODULE SCREW ASH RECEIVER HOUSING MOUNTING HOLES POWER OUTLET CIGAR LIGHTER
Fig. 17 Glove Box Remove/Install
DRILL OUT RIVETS SCREWS
Fig. 18 Glove Box Components
BEZEL SCREWS HANDLE SCREW HINGE LATCH SCREWS BIN INNER DOOR PANEL
GLOVE BOX LATCH AND HANDLE
group.
(2) Remove the gl ove box hi nge and gl ove box bi n
(3) Remove the two bezel screws, two l atch screws,
and one handl e screw from the gl ove box i nner door
panel .
(4) Remove the i nner door panel from the gl ove
box door.
(5) Remove the second gl ove box l atch handl e
screw (Fi g. 19).
(6) Remove the l atch and handl e from the gl ove
box door as a uni t.
GLOVE BOX LOCK CYLINDER
(1) Remove the gl ove box l atch and handl e as
(2) I nsert the key i nto the gl ove box l ock cyl i nder.
(3) I nsert a smal l screwdri ver i nto the retai ni ng
tumbl er rel ease sl ot and depress the retai ni ng tum-
bl er (Fi g. 20).
(4) Pul l the l ock cyl i nder out of the l atch handl e by
usi ng a gentl e twi sti ng and pul l i ng acti on on the key.
COWL TOP TRIM PANEL
INJURY.
cabl e.
(2) Usi ng a wi de fl at-bl aded tool such as a tri m
sti ck, gentl y pry the cowl top tri m panel off of the
i nstrument panel top pad (Fi g. 21).
(3) Pul l the panel up far enough to unpl ug the
wi re harness connector for the sol ar sensor, or to
remove the sol ar sensor from the cowl top tri m, i f the
vehi cl e i s so equi pped.
(4) Remove the cowl top tri m panel from the vehi -
cl e.
INSTRUMENT PANEL TOP PAD
INJURY.
cabl e.
Fig. 19 Glove Box Latch and Handle Remove/Install
LATCH LATCH HANDLE SCREW
Fig. 20 Glove Box Lock Cylinder Remove/Install
RETAINING TUMBLER RELEASE SLOTLATCH HANDLE KEY LOCK CYLINDER
Fig. 21 Cowl Top Trim Remove/Install
COWL TOP TRIM PANEL INSTRUMENT PANEL
(2) Remove both swi tch pod bezel s, the cl uster
bezel , the knee bl ocker, the gl ove box modul e, and
the cowl top tri m panel . See the procedures i n thi s
group.
(3) I f the vehi cl e i s so equi pped, remove the screw
that secures the auto headl amp l i ght sensor/vehi cl e
theft securi ty system l amp near the defroster duct
outl et and move i t for cl earance of the i nstrument
panel top pad.
(4) Remove the screws around the peri meter of the
i nstrument panel top pad that secure the top pad to
the i nstrument panel armature.
(5) Li ft the top pad off of the i nstrument panel
armature and remove i t from the vehi cl e.
JUNCTION BLOCK
INJURY.
cabl e.
(2) Remove the fuse access panel by unsnappi ng i t
from the ri ght cowl si de tri m panel .
(3) Remove the push nut that secures the ri ght
cowl si de tri m panel to the juncti on bl ock stud (Fi g.
22).
(4) Remove the two screws that secure the ri ght
cowl si de tri m panel to the ri ght front door openi ng
tri m.
(5) Remove the ri ght cowl si de tri m panel .
(6) Unpl ug al l of the wi re harness connectors from
the juncti on bl ock cavi ti es.
(7) Remove the bol t that secures the juncti on bl ock
to the cowl si de panel (Fi g. 23).
(8) On Left-Hand Dri ve (LHD) model s onl y, l i ft
upwards on the juncti on bl ock to remove i ts sl i de-tab
mount off of the mounti ng bracket on the ri ght cowl
si de panel .
(9) Remove the juncti on bl ock from the vehi cl e.
INSTRUMENT PANEL ASSEMBLY
INJURY.
cabl e.
thi s group.
Fig. 22 Right Cowl Side Trim Panel Remove/Install
RIGHT COWL SIDE TRIM PUSH NUT SCREWS JUNCTION BLOCK
Fig. 23 Junction Block Remove/Install
RELAYS MOUNTING BOLT CIRCUIT BREAKER FUSES
(3) Remove the knee bl ocker as descri bed i n thi s
group.
(4) Remove the bol ts that secure the l ower i nstru-
ment panel rei nforcement to the i nstrument panel
armature and remove the rei nforcement (Fi g. 24).
(5) Remove the upper and l ower steeri ng col umn
shrouds. Refer to Group 19 - Steeri ng for the proce-
dures.
(6) Unpl ug al l of the wi re harness connectors on
the steeri ng col umn-mounted components and
swi tches.
(7) Remove the three nuts that secure the steeri ng
col umn toe pl ate at the base of the steeri ng col umn.
(8) Remove the two nuts that secure the steeri ng
col umn mounti ng bracket to the studs on the steer-
i ng col umn and brake pedal support. Lower the
steeri ng col umn to the fl oor.
(9) Remove both cowl si de tri m panel s. Refer to
Group 23 - Body for the procedures.
(10) Unpl ug the i nstrument panel to body wi re
harness connector under the l eft end of the i nstru-
ment panel .
(11) Unpl ug the brake l amp swi tch wi re harness
connector.
(12) Unpl ug the i nstrument panel to heater-A/C
housi ng vacuum harness connector (manual temper-
ature control onl y) and wi re harness connector
l ocated under the passenger si de end of the i nstru-
ment panel .
(13) Unpl ug the radi o antenna coaxi al cabl e con-
nector near the ri ght cowl si de panel .
(14) Unpl ug al l of the i nstrument panel wi re har-
ness connectors from the juncti on bl ock on the ri ght
cowl si de panel .
(15) I f the vehi cl e i s so equi pped, di sconnect the
i n-car temperature sensor aspi rator hose at the cou-
pl i ng near the passenger si de of the transmi ssi on
fl oor tunnel .
(16) On Left-Hand Dri ve (LHD) model s onl y,
remove the ash recei ver and remove the screw i n the
back of the ash recei ver housi ng that secures the
i nstrument panel armature to the heater-A/C hous-
i ng.
(17) Pul l back the fl oor carpet on the transmi ssi on
fl oor tunnel from the base of the i nstrument panel
center bezel and remove the two bol ts that secure the
i nstrument panel center bracket to the fl oor.
(18) Remove the two bol ts that secure the i nstru-
ment panel center bracket to the dri ver si de of the
transmi ssi on fl oor tunnel .
(19) Remove the bol t that secures the i nstrument
panel armature to the steeri ng col umn and brake
pedal support.
Fig. 24 Instrument Panel Assembly Remove/Install
STUDS COWL TOP TRIM PANEL LOWER INSTRUMENT PANEL REINFORCEMENT BOLT NUT U-NUT BOLT SCREW BOLT ASH RECEIVER
INBOARD
SWITCH
POD
BEZEL
KNEE BLOCKER SCREW OUTBOARD SWITCH POD BEZEL BOLT FWD BOLT
(20) Remove the two bol ts that secure the ends of
the i nstrument panel armature to the cowl si de pan-
el s.
(21) Remove the cowl top tri m panel as descri bed
i n thi s group.
the i nstrument panel armature to the wi ndshi el d
fence.
(23) Remove the four nuts that secure the top of
the i nstrument panel armature to the studs on the
wi ndshi el d fence.
(24) Wi th the ai d of an assi stant, l i ft the i nstru-
ment panel off of the wi ndshi el d fence studs and
maneuver the assembl y out of the vehi cl e through
the passenger si de front door.
Ti ghten the mounti ng hardware as fol l ows:
I nstrument panel center bracket to fl oor pan
transmi ssi on tunnel fasteners - 28 Nm (250 i n. l bs.)
I nstrument panel to wi ndshi el d fence bol ts and
nuts - 12 Nm (105 i n. l bs.)
I nstrument panel to cowl si de panel bol ts - 12
Nm (105 i n. l bs.)
I nstrument panel to steeri ng col umn support
bol t - 12 Nm (105 i n. l bs.)
Knee bl ocker mounti ng screws - 2.2 Nm (20 i n.
l bs.).
INSTRUMENT PANEL SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GRAPHIC DISPLAY MODULE . . . . . . . . . . . . . . 3
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . 3
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 2
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 2
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 4
AIRBAG INDICATOR LAMP . . . . . . . . . . . . . . . . 6
ANTI-LOCK BRAKE SYSTEM LAMP . . . . . . . . . . 7
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . 7
CHECK GAUGES LAMP . . . . . . . . . . . . . . . . . . . 7
CLUSTER ILLUMINATION LAMP . . . . . . . . . . . . 7
COOLANT TEMPERATURE GAUGE . . . . . . . . . . 5
CRUISE-ON INDICATOR LAMP . . . . . . . . . . . . . 8
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEADLAMP HIGH BEAM INDICATOR LAMP . . . 8
LOW FUEL WARNING LAMP . . . . . . . . . . . . . . . 8
MASTER LIGHTING INDICATOR LAMP . . . . . . . 8
ODOMETER AND TRIP ODOMETER . . . . . . . . . 5
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . . 5
SEAT BELT REMINDER LAMP . . . . . . . . . . . . . . 9
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 6
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 6
UPSHIFT INDICATOR LAMP . . . . . . . . . . . . . . . 9
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WAIT-TO-START LAMP . . . . . . . . . . . . . . . . . . . 9
WATER-IN-FUEL LAMP . . . . . . . . . . . . . . . . . . . 9
AIRBAG INDICATOR LAMP . . . . . . . . . . . . . . . 12
ANTI-LOCK BRAKE SYSTEM LAMP . . . . . . . . . 12
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . 13
CHECK GAUGES LAMP . . . . . . . . . . . . . . . . . . 13
CLUSTER ILLUMINATION LAMP . . . . . . . . . . . 13
COOLANT TEMPERATURE GAUGE . . . . . . . . . 10
CRUISE-ON INDICATOR LAMP . . . . . . . . . . . . 13
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . 10
GRAPHIC DISPLAY MODULE . . . . . . . . . . . . . 14
HEADLAMP HIGH BEAM INDICATOR LAMP . . 15
LOW FUEL WARNING LAMP . . . . . . . . . . . . . . 15
MASTER LIGHTING INDICATOR LAMP . . . . . . 16
ODOMETER AND TRIP ODOMETER . . . . . . . . 11
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . 11
SEAT BELT REMINDER LAMP . . . . . . . . . . . . . 16
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 11
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 11
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . 17
UPSHIFT INDICATOR LAMP . . . . . . . . . . . . . . 17
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WAIT-TO-START LAMP . . . . . . . . . . . . . . . . . . 20
WATER-IN-FUEL LAMP . . . . . . . . . . . . . . . . . . 20
SERVICE PROCEDURES
BODY CONTROL MODULE . . . . . . . . . . . . . . . 26
CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . . . . . 28
CLUSTER BEZEL . . . . . . . . . . . . . . . . . . . . . . . 23
CLUSTER BULB . . . . . . . . . . . . . . . . . . . . . . . . 25
CLUSTER LENS, HOOD, AND MASK . . . . . . . . 24
COWL TOP TRIM PANEL . . . . . . . . . . . . . . . . . 31
GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GLOVE BOX COMPONENTS . . . . . . . . . . . . . . 30
GLOVE BOX LAMP AND SWITCH . . . . . . . . . . 28
GLOVE BOX LATCH STRIKER . . . . . . . . . . . . . 28
GLOVE BOX MODULE . . . . . . . . . . . . . . . . . . . 27
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INFORMATION CENTER . . . . . . . . . . . . . . . . 27
INBOARD SWITCH POD . . . . . . . . . . . . . . . . . 26
INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . 32
INSTRUMENT PANEL CENTER BEZEL . . . . . . 29
INSTRUMENT PANEL TOP PAD . . . . . . . . . . . . 31
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 31
KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . . 23
OUTBOARD SWITCH POD . . . . . . . . . . . . . . . 26
POWER OUTLET DOOR . . . . . . . . . . . . . . . . . 29
POWER OUTLET . . . . . . . . . . . . . . . . . . . . . . . 29
SWITCH POD BEZEL . . . . . . . . . . . . . . . . . . . . 23
GENERAL INFORMATION
INTRODUCTION
Thi s group i s responsi bl e for coveri ng the vehi cl e
i nstrument panel . However, because the i nstrument
panel serves as the command center of the vehi cl e, i t
i s a very compl ex uni t. The i nstrument panel i s
desi gned to house the control s and moni tors for stan-
dard and opti onal powertrai ns, cl i mate control sys-
tems, audi o systems, l i ghti ng systems, safety
systems, and many other comfort or conveni ence
i tems. I t i s al so desi gned so that al l of the control s
and moni tors can be safel y reached and vi ewed by
the vehi cl e operator, whi l e sti l l al l owi ng rel ati ve ease
of access to these i tems for servi ce.
Compl ete servi ce i nformati on coverage for al l of the
systems and components housed i n the i nstrument
panel i n thi s secti on of the servi ce manual woul d not
be practi cal . I t woul d resul t i n a great deal of dupl i -
cati on and make thi s group too l arge for the i nforma-
ti on to be easi l y accessed and used. Therefore, the
i nformati on found i n thi s group has been l i mi ted as
fol l ows:
General I nformati on - Covers non-el ectri cal com-
ponents and features of the i nstrument panel that
are not rel ated to other systems.
Descri pti on and Operati on - Covers gauges and
thei r sendi ng uni ts, warni ng l amps and thei r
swi tches, and i nstrument panel i l l umi nati on l amps.
Di agnosi s and Testi ng - Covers gauges and thei r
sendi ng uni ts, warni ng l amps and thei r swi tches,
and i nstrument panel i l l umi nati on l amps.
Removal and I nstal l ati on - Covers components
i nstal l ed on or i n the i nstrument panel that requi re
removal for di agnosi s or servi ce of i nstrument panel
components covered i n thi s group.
For more i nformati on on components or systems
not covered above, refer to the proper group i n thi s
manual . I f you are uncertai n as to the proper group,
refer to the Component and System I ndex at the
back of thi s manual . Refer to Group 8W - Wi ri ng
grams.
INSTRUMENT PANEL
Modul ar i nstrument panel constructi on al l ows al l
of the gauges and control s to be servi ced from the
front of the panel . I n addi ti on, most of the i nstru-
ment panel wi ri ng or heati ng and ai r condi ti oni ng
components can be accessed wi thout compl ete i nstru-
ment panel removal . I f necessary, the i nstrument
panel can be rol l ed-down and removed from the vehi -
cl e as an assembl y.
Removal of the swi tch pod bezel s al l ows access to
most swi tches and the cl i mate control s. Removal of
the i nstrument cl uster bezel al l ows access to the
cl uster assembl y and the radi o. Removal of the cl us-
ter assembl y al l ows access to the i ndi vi dual gauges,
i l l umi nati on and i ndi cator l amp bul bs, and most of
the i nstrument panel wi ri ng.
Removal of the steeri ng col umn cover/knee bl ocker
provi des access to the steeri ng col umn mounts, the
body control modul e, the gearshi ft i nterl ock mecha-
ni sm, and addi ti onal i nstrument panel and steeri ng
col umn wi ri ng. Removal of the gl ove box modul e and
center bezel uni t al l ows access to the Vehi cl e I nfor-
mati on Center (VI C), Graphi c Di spl ay Modul e
(GDM), addi ti onal i nstrument panel wi ri ng, the
i n-vehi cl e temperature sensor, and other heati ng and
ai r condi ti oni ng components.
Removal of the i nstrument panel cowl top tri m
panel al l ows access to the i nstrument panel speak-
ers, the sol ar sensor, and the automati c headl amp
l i ght sensor/vehi cl e theft securi ty system l amp.
Removal of the i nstrument panel top pad al l ows
access to the passenger si de ai rbag modul e.
INSTRUMENT CLUSTER
One basi c i nstrument cl uster opti on i s offered on
Grand Cherokee model s. Thi s cl uster i s an el ectrome-
chani cal uni t that uti l i zes i ntegrated ci rcui try and
i nformati on carri ed on the Chrysl er Col l i si on Detec-
ti on (CCD) data bus network for control of al l gauges
and most i ndi cator l amps. Thi s cl uster al so i ncorpo-
rates a vacuum fl uorescent di spl ay tube for the di gi -
tal odometer and tri p odometer di spl ay functi ons.
Some vari ati ons of the cl uster exi st due to opti onal
equi pment and regul atory requi rements.
The cl uster i ncl udes the fol l owi ng anal og gauges:
Fuel gauge
Oi l pressure gauge
Speedometer
Tachometer
Vol tmeter.
Thi s cl uster i ncl udes provi si ons for the fol l owi ng
i ndi cator l amps:
Ai rbag i ndi cator l amp
Anti -l ock brake system l amp
Check gauges l amp
Crui se-on i ndi cator l amp
Headl amp hi gh beam i ndi cator l amp
Low fuel warni ng l amp
Mal functi on i ndi cator (Check Engi ne) l amp
Master l i ghti ng i ndi cator l amp
Seat bel t remi nder l amp
Turn si gnal i ndi cator l amps
Upshi ft i ndi cator l amp (manual transmi ssi on)
Wai t-to-start l amp (di esel engi ne)
Water-i n-fuel l amp (di esel engi ne).
A Graphi c Di spl ay Modul e (GDM) i s standard
equi pment on al l Grand Cherokee model s, unl ess the
vehi cl e i s equi pped wi th the opti onal Vehi cl e I nfor-
mati on Center (VI C). The GDM i s mounted i n the
l ower center stack area of the i nstrument panel ,
above the ash recei ver and bel ow the heater-A/C con-
trol s.
The di spl ay consi sts of a back-l i t screen wi th a
vehi cl e outl i ne. The two rear wheel s of the vehi cl e
are i l l umi nated by a l amp when the transfer case i s
engaged i n any two-wheel dri ve operati ng mode. The
two front wheel s are al so i l l umi nated when the
transfer case i s engaged i n any four-wheel dri ve oper-
ati ng mode.
The GDM al so has up to three l amps, whi ch i ndi -
cate whether the four-wheel dri ve mode sel ected i s
Lo, Part-Ti me, or Ful l -Ti me. The number of opera-
ti onal i ndi cator l amps may vary, dependi ng upon the
opti onal four-wheel dri ve transfer case i n the vehi cl e.
A swi tch on the transfer case i s hard-wi red to the
GDM to i l l umi nate the proper wheel s and i ndi cator
l amps.
The GDM bul bs can be servi ced. However, i f any
other part of the GDM i s damaged or faul ty, the
enti re GDM must be repl aced.
The Vehi cl e I nformati on Center (VI C) i s an avai l -
abl e opti on on Grand Cherokee model s. The VI C
modul e repl aces the standard equi pment Graphi c
Di spl ay Modul e. The VI C i s mounted i n the l ower
center stack area of the i nstrument panel , above the
ash recei ver and bel ow the heater-A/C control s.
The VI C consi sts of a mul ti col ored vacuum fl uores-
cent di spl ay screen wi th a vehi cl e outl i ne. The VI C i s
abl e to di spl ay four functi ons i n a choi ce of fi ve l an-
guages. The di spl ay functi ons i ncl ude:
Current ti me (12 or 24 hour cl ock), day, and date
al ert the dri ver of a mal functi on i n a moni tored sys-
tem
Provi de servi ce remi nders or the di stance to the
next servi ce i nterval
The current transfer case mode of operati on
(four-wheel dri ve model s).
The di spl ay l anguage choi ces i ncl ude:
Engl i sh
French
German
I tal i an
Spani sh.
The VI C recei ves i nput from hard-wi red sensors
and over the Chrysl er Col l i si on Detecti on (CCD) data
bus network. I n response to these i nputs the VI C
offers a combi nati on of graphi c and message di spl ays,
and provi des requests for audi bl e chi me al erts to the
Body Control Modul e (BCM) on the CCD data bus.
on the VI C control s, operati on, and setti ng proce-
dures. For di agnosi s of the VI C modul e or the CCD
data bus, refer to the proper Body Di agnosti c Proce-
dures manual . The VI C modul e cannot be repai red. I f
damaged or faul ty, the enti re modul e must be
repl aced.
GAUGE
Wi th the i gni ti on swi tch i n the On or Start posi -
ti ons, vol tage i s suppl i ed to al l gauges through the
i nstrument cl uster el ectroni c ci rcui t board. Wi th the
i gni ti on swi tch i n the Off posi ti on, vol tage i s not sup-
pl i ed to the gauges. The gauges do not accuratel y
i ndi cate any vehi cl e condi ti on unl ess the i gni ti on
swi tch i s i n the On or Start posi ti ons.
Al l gauges, except the odometer, are ai r core mag-
neti c uni ts. Two fi xed el ectromagneti c coi l s are
l ocated wi thi n the gauge. These coi l s are wrapped at
ri ght angl es to each other around a movabl e perma-
nent magnet. The movabl e magnet i s suspended
wi thi n the coi l s on one end of a shaft. The gauge nee-
dl e i s attached to the other end of the shaft.
One of the coi l s has a fi xed current fl owi ng
through i t to mai ntai n a constant magneti c fi el d
strength. Current fl ow through the second coi l
changes, whi ch causes changes i n i ts magneti c fi el d
strength. The current fl owi ng through the second coi l
i s changed by the i nstrument cl uster el ectroni c ci r-
cui try i n response to messages recei ved on the
The gauge needl e moves as the movabl e permanent
magnet al i gns i tsel f to the changi ng magneti c fi el ds
created around i t by the el ectromagnets. These
gauges al so feature a smal l fi xed permanent magnet
whi ch wi l l cause the gauge needl es to return to zero
after the i gni ti on swi tch i s turned to the Off posi ti on.
INDICATOR LAMP
I ndi cator l amps are l ocated i n the i nstrument cl us-
ter, and i n the Graphi c Di spl ay Modul e (GDM) or the
Vehi cl e I nformati on Center (VI C). Those l amps
wi thi n the i nstrument cl uster are served by the cl us-
ter ci rcui t board and wi re harness connectors. Those
l amps l ocated i n the GDM or VI C modul es are served
by the GDM or VI C ci rcui t board and wi re harness
connectors.
Most of the i ndi cator l amps i n the i nstrument cl us-
ter and VI C modul e are control l ed by the i nstrument
cl uster or VI C modul e el ectroni c ci rcui try i n response
to messages recei ved over the Chrysl er Col l i si on
Detecti on (CCD) data bus network from the Body
Control Modul e (BCM), Powertrai n Control Modul e
(PCM), and Ai rbag Control Modul e (ACM). Onl y the
anti -l ock brake system l amp, four-wheel dri ve i ndi ca-
tor l amps, l amp outage warni ng l amp, l ow cool ant
l evel warni ng l amp, l ow washer fl ui d warni ng l amp,
master l i ghti ng i ndi cator l amp, and turn si gnal i ndi -
cator l amps are hard-wi red.
BODY CONTROL MODULE
supports or control s, i ncl ude:
Chi mes
Automati c headl amp control
Headl amp del ay
Headl amps on wi th i gni ti on off and dri ver door
open warni ng
Key i n i gni ti on wi th i gni ti on off and dri ver door
open warni ng
Automati c funeral or parade mode
Panel l amp di mmi ng
Vehi cl e Theft Securi ty System (VTSS)
Vehi cl e i mmobi l i zer system
I l l umi nated entry
Heated rear wi ndow and heated outsi de mi rror
control
I ntermi ttent wi pe control
Moni tori ng and transmi tti ng door, hood, l i ftgate,
l i ftgl ass ajar data
Moni tori ng and transmi tti ng outsi de ambi ent
temperature data
Moni tori ng and transmi tti ng ai r condi ti oni ng
sel ect swi tch data
Courtesy l amp ti me-out
Gul f coast country over-speed warni ng
Door l ock i nhi bi t
El ectroni c odometer and tri p odometer
Check gauges l amp
Hi gh beam i ndi cator l amp
Seatbel t remi nder l amp and chi me
Speed sensi ti ve i ntermi ttent wi pe
Fog l amp control
El ectromechani cal i nstrument cl uster
BCM di agnosti c support
Vehi cl e I nformati on Center (VI C) support
Rol l i ng door l ocks
Horn chi rp upon door l ock wi th Remote Keyl ess
Entry (RKE)(programmabl e)
Low fuel warni ng chi me (programmabl e)
Headl i ghts on wi th wi pers (programmabl e - wi th
automati c headl amps onl y)
outboard swi tch pod. For di agnosi s of the BCM or the
CCD data bus, refer to the proper Body Di agnosti c
Procedures manual . The BCM can onl y be servi ced
by an authori zed el ectroni c repai r stati on. Refer to
the l atest Warranty Pol i ci es and Procedures manual
for a current l i sti ng of authori zed el ectroni c repai r
stati ons.
JUNCTION BLOCK
The juncti on bl ock i s mounted on the ri ght cowl
si de ki ck panel bel ow the ri ght end of the i nstrument
panel . I t i s conceal ed behi nd the ri ght cowl si de tri m.
The juncti on bl ock serves to si mpl i fy and central i ze
numerous el ectri cal components.
The juncti on bl ock has cavi ti es for up to twenty-
two bl ade-type fuses, three ci rcui t breakers, si x I SO
mi cro-rel ays, and an el ectroni c combi nati on fl asher
uni t. I t al so el i mi nates the need for numerous spl i ce
connecti ons and serves i n the pl ace of a bul khead
connector between the engi ne compartment, i nstru-
ment panel , and body wi re harnesses.
The ri ght cowl si de tri m panel has a snap-fi t access
cover that can be removed for servi ce of the juncti on
bl ock fuses, but the cowl si de tri m panel must be
removed for servi ce of other juncti on bl ock compo-
nents. The juncti on bl ock cannot be repai red and, i f
The cool ant temperature gauge gi ves an i ndi cati on
of the engi ne cool ant temperature. The i nstrument
cl uster ci rcui try control s the gauge poi nter posi ti on.
The i nstrument cl uster ci rcui try cal cul ates the
proper gauge poi nter posi ti on based upon an engi ne
cool ant temperature message recei ved from the Pow-
ertrai n Control Modul e (PCM) on the Chrysl er Col l i -
si on Detecti on (CCD) data bus.
The PCM uses an i nput from the engi ne cool ant
temperature sensor and i nternal programmi ng to
deci de what engi ne cool ant temperature message i s
requi red. The PCM then sends the proper message to
the i nstrument cl uster and the Body Control Modul e
(BCM) on the CCD data bus.
The BCM moni tors the PCM cool ant temperature
messages. I f the PCM message i ndi cates that cool ant
temperature i s hi gh or cri ti cal , the BCM sends a
message to the i nstrument cl uster to turn on the
Check Gauges l amp and to dri ve the cool ant temper-
ature gauge needl e to the correspondi ng hi gh or cri t-
i cal posi ti on of the gauge scal e.
i n a threaded hol e that penetrates a cool ant passage
of the engi ne. I t i s a thermi stor-type sensor that
changes i ts i nternal resi stance wi th changes i n
engi ne cool ant temperature. Refer to Group 14 - Fuel
Systems for more i nformati on on the PCM and the
cool ant temperature sensor.
FUEL GAUGE
The fuel gauge gi ves an i ndi cati on of the l evel of
fuel i n the fuel tank. The i nstrument cl uster ci rcui try
posi ti on based upon a fuel l evel message recei ved
The PCM uses an i nput from the fuel gauge send-
i ng uni t and i nternal programmi ng to deci de what
fuel l evel message i s requi red. The PCM then sends
CCD data bus. I f the PCM detects a short or open i n
the fuel l evel sendi ng uni t ci rcui t, i t sends a message
on the CCD data bus that wi l l cause the i nstrument
cl uster ci rcui try to posi ti on the fuel gauge needl e at
the Empty stop.
The fuel gauge sendi ng uni t i s mounted to the el ec-
tri c fuel pump modul e l ocated i nsi de the fuel tank.
The sendi ng uni t has a fl oat attached to the end of a
swi ng-arm. The fl oat moves up or down wi thi n the
fuel tank as the fuel l evel changes. As the fl oat
moves, an el ectri cal contact on the pi vot end of the
swi ng-arm wi pes across a resi stor coi l , whi ch changes
the i nternal el ectri cal resi stance of the sendi ng uni t.
Refer to Group 14 - Fuel Systems for more i nforma-
ti on on the PCM and for the fuel gauge sendi ng uni t
The odometer and the tri p odometer share the
same vacuum fl uorescent di gi tal di spl ay tube i n the
i nstrument cl uster ci rcui t board. Each gi ves an i ndi -
cati on of the di stance the vehi cl e has travel l ed. How-
ever; by depressi ng the reset knob on the face of the
i nstrument cl uster, the di spl ay can be swi tched from
odometer to tri p odometer. Depressi ng the reset knob
for l onger than two seconds whi l e i n the tri p odome-
ter mode wi l l reset the tri p odometer to zero. The
odometer and tri p odometer di spl ay the di stance val -
ues that are recei ved from the Body Control Modul e
data bus.
The BCM uses an i nput from the Powertrai n Con-
trol Modul e (PCM) and i nternal programmi ng to cal -
cul ate the di stance val ue. The PCM uses an i nput
from the Vehi cl e Speed Sensor (VSS) to send a di s-
tance pul se si gnal to the BCM on the CCD data bus.
The BCM stores both the odometer and tri p odometer
di stance i nformati on and sends the proper val ue to
the i nstrument cl uster based upon i gni ti on key-on
and tri p odometer reset knob messages recei ved on
the CCD data bus.
I f the i nstrument cl uster i s not recei vi ng di stance
i nformati on on the CCD data bus when the i gni ti on
swi tch i s turned to the On posi ti on, the odometer di s-
pl ay wi l l remai n bl ank. I f the i nstrument cl uster
does not recei ve a di stance message on the CCD data
bus after the i gni ti on swi tch has been turned to the
On posi ti on, the i nstrument panel ci rcui try wi l l
i nsert the l ast normal l y di spl ayed di stance i n the
odometer di spl ay.
i n i naccurate odometer readi ngs. Refer to Group 14 -
the VSS. Refer to Group 21 - Transmi ssi on for more
i nformati on on the speedometer pi ni on gear.
OIL PRESSURE GAUGE
The oi l pressure gauge gi ves an i ndi cati on of the
engi ne oi l pressure. The i nstrument cl uster ci rcui try
posi ti on based upon an engi ne oi l pressure message
The PCM uses an i nput from the engi ne oi l pres-
sure sensor and i nternal programmi ng to deci de
what engi ne oi l pressure message i s requi red. The
PCM then sends the proper message to the i nstru-
ment cl uster and the Body Control Modul e (BCM) on
the CCD data bus.
The BCM moni tors the PCM engi ne oi l pressure
messages. I f the PCM message i ndi cates that engi ne
oi l pressure i s too l ow, the BCM sends a message to
the i nstrument cl uster to turn on the Check Gauges
l amp and to dri ve the oi l pressure gauge needl e to
the zero end of the gauge scal e.
The engi ne oi l pressure sensor i s i nstal l ed i n a
threaded hol e that penetrates an oi l passage of the
engi ne. The engi ne oi l pressure sensor contai ns a
fl exi bl e di aphragm and a vari abl e resi stor coi l . The
di aphragm moves i n response to changes i n the
engi ne oi l pressure, whi ch changes the i nternal el ec-
tri cal resi stance of the sensor. Refer to Group 14 -
the engi ne oi l pressure sensor.
SPEEDOMETER
The speedometer gi ves an i ndi cati on of the current
vehi cl e speed. The i nstrument cl uster ci rcui try con-
posi ti on based upon a vehi cl e speed message recei ved
The PCM uses an i nput from the Vehi cl e Speed
Sensor (VSS) and i nternal programmi ng to deci de
what vehi cl e speed message i s requi red. The PCM
cl uster on the CCD data bus.
i n i naccurate speedometer readi ngs. Refer to Group
14 - Fuel Systems for more i nformati on on the PCM
and the VSS. Refer to Group 21 - Transmi ssi on for
more i nformati on on the speedometer pi ni on gear.
TACHOMETER
The tachometer gi ves an i ndi cati on of the engi ne
speed i n revol uti ons-per-mi nute (rpm). The i nstru-
ment cl uster ci rcui try control s the gauge poi nter
posi ti on. The i nstrument cl uster ci rcui try cal cul ates
the proper gauge poi nter posi ti on based upon an
engi ne speed message recei ved from the Powertrai n
Control Modul e (PCM) on the Chrysl er Col l i si on
The PCM uses an i nput from the crankshaft posi -
ti on sensor and i nternal programmi ng to deci de what
engi ne speed message i s requi red. The PCM then
sends the proper message to the i nstrument cl uster
on the CCD data bus.
The crankshaft posi ti on sensor i s i nstal l ed near the
rear of the engi ne, where i t i s ai med at the tri gger
wheel attached to the rear fl ange of the crankshaft.
For model s wi th a gasol i ne engi ne, refer to Group 8D
- I gni ti on Systems for more i nformati on on the
crankshaft posi ti on sensor. For model s wi th a di esel
engi ne, refer to Group 14 - Fuel Systems for more
i nformati on on the crankshaft posi ti on sensor.
VOLTMETER
The vol tmeter gi ves an i ndi cati on of the el ectri cal
system vol tage. The i nstrument cl uster ci rcui try con-
posi ti on based upon a system vol tage message
The PCM uses an i nput from the el ectri cal system
and i nternal programmi ng to deci de what system
vol tage message i s requi red. The PCM then sends
CCD data bus.
Refer to Group 14 - Fuel System for more i nforma-
ti on on the PCM. Refer to Group 8C - Chargi ng Sys-
tem for more i nformati on on chargi ng system
components and di agnosi s.
The ai rbag i ndi cator l amp gi ves an i ndi cati on when
the ai rbag system i s faul ty or i noperati ve. The l amp
i s turned on by the i nstrument cl uster ci rcui try for
about seven seconds when the i gni ti on swi tch i s
the Ai rbag Control Modul e (ACM) on the Chrysl er
Col l i si on Detecti on (CCD) data bus.
The ACM conti nual l y moni tors the ai rbag system
ci rcui ts and sensors to deci de whether the system i s
i n good operati ng condi ti on. The ACM then sends the
proper message to the i nstrument cl uster on the
CCD data bus to turn the l amp on or off. I f the ACM
turns the l amp on after the bul b test, i t i ndi cates the
ACM has detected a system mal functi on and/or that
the ai rbag system has become i noperati ve. Each ti me
the i nstrument cl uster ci rcui try recei ves a l amp-on
message from the ACM, i t wi l l l i ght the l amp for
twel ve seconds or the durati on of the ai rbag system
mal functi on, whi chever i s l onger.
The ai rbag i ndi cator l amp al so has a l amp backup
feature. Fol l owi ng the seat bel t remi nder l amp di s-
pl ay functi on, i f an i noperati ve ai rbag warni ng l amp
ci rcui t was detected duri ng the bul b test sequence,
the i nstrument cl uster ci rcui try wi l l fl ash the seat
bel t remi nder l amp on and off for about twenty sec-
onds. I f the seat bel t remi nder l amp fl ashes l onger
than twenty seconds, or fl ashes at any ti me other
than about twenty seconds after the i ni ti al i gni -
ti on-on sequence, i t i ndi cates an ai rbag system faul t
has been detected and that the ai rbag i ndi cator l amp
i s i noperati ve.
Refer to Group 8M - Passi ve Restrai nt Systems for
more i nformati on on the ai rbag system.
The Anti -Lock Brake System (ABS) l amp gi ves an
i ndi cati on when the ABS system i s faul ty or i noper-
ati ve. The l amp i s hard-wi red i n the i nstrument cl us-
ter, and i s compl etel y control l ed by the Control l er
Anti -l ock Brake (CAB). I t recei ves battery vol tage
through the i nstrument cl uster fused i gni ti on swi tch
output feed ci rcui t, and i s grounded by the CAB. The
l amp i s turned on by the CAB for about two seconds
when the i gni ti on swi tch i s turned to the On posi ti on
as a bul b test. After the bul b test, the CAB turns the
l amp on or off based upon the resul ts of the ABS sys-
tem sel f-tests.
The CAB conti nual l y moni tors the ABS ci rcui ts
and sensors to deci de whether the system i s i n good
operati ng condi ti on. I f the CAB turns the l amp on
after the bul b test, i t i ndi cates that the CAB has
detected a system mal functi on and/or that the ABS
system has become i noperati ve. Refer to Group 5 -
Brakes for more i nformati on.
BRAKE WARNING LAMP
The brake warni ng l amp gi ves an i ndi cati on when
the parki ng brake i s appl i ed, or when the pressures
i n the two hal ves of the spl i t brake hydraul i c system
are unequal . The l amp i s turned on by the i nstru-
ment cl uster ci rcui try for about four seconds when
message recei ved from the Body Control Modul e
data bus.
The BCM uses i nputs from the parki ng brake
swi tch and the brake warni ng swi tch to deci de
whether the brake warni ng l amp shoul d be on or off.
The BCM then sends the proper message to the
l amp on or off.
The brake warni ng swi tch cl oses to ground when i t
senses unequal hydraul i c pressures i n the two hal ves
of the spl i t brake hydraul i c system, possi bl y due to
l ow brake fl ui d l evel or brake fl ui d l eakage. The
parki ng brake swi tch cl oses to ground when the
parki ng brake i s appl i ed. Refer to Group 5 - Brakes
CHECK GAUGES LAMP
The check gauges l amp gi ves an i ndi cati on when
certai n gauges refl ect a condi ti on requi ri ng i mmedi -
ate attenti on. The l amp i s turned on by the i nstru-
ment cl uster ci rcui try for about three seconds after
message recei ved from ei ther the Body Control Mod-
ul e (BCM) or the Powertrai n Control Modul e (PCM)
The BCM and PCM use several i nputs to deci de
whether a condi ti on exi sts requi ri ng the check
gauges l amp to be turned on. The responsi bl e modul e
check gauges l amp-on message, i t sends a chi me
request message to the BCM on the CCD data bus
for a chi me tone to sound.
The condi ti ons moni tored and the responsi bl e mod-
ul es are:
Engi ne cool ant temperature i s hi gh or cri ti cal
(BCM)
Engi ne oi l pressure i s l ow (BCM)
Chargi ng system fai l ure (PCM)
System vol tage i s hi gh (PCM).
When the park or head l amps are on, the cl uster
i l l umi nati on l amps l i ght. I l l umi nati on bri ghtness i s
adjusted by sl i di ng the panel di mmer swi tch knob
(downwards to di m, upwards to bri ghten). Each of
the i nstrument cl uster i l l umi nati on l amps recei ves
Control Modul e (BCM) on the hard-wi red panel
l amps dri ver ci rcui t. The BCM moni tors the panel
di mmer resi stor swi tch to determi ne the desi red di m-
mi ng l evel , then adjusts the pul se-wi dth si gnal
accordi ngl y.
The BCM al so sends the proper panel l amps di m-
mi ng l evel message on the Chrysl er Col l i si on Detec-
ti on (CCD) data bus to control the di mmi ng l evel s of
the vari ous vacuum fl uorescent di spl ays. Al l modul es
on the CCD data bus wi th vacuum fl uorescent di s-
pl ays (i nstrument cl uster, radi o, mi ni tri p computer,
vehi cl e i nformati on center) recei ve thi s message and
adjust thei r di mmi ng l evel s to match that of the
i ncandescent cl uster i l l umi nati on bul bs dri ven
di rectl y by the BCM.
Vehi cl es equi pped wi th the automati c headl amps
opti on have an automati c funeral mode or parade
mode. I n thi s mode, the BCM uses an i nput from the
automati c headl amp l i ght sensor to determi ne the
ambi ent l i ght l evel s. I f the BCM deci des that the
exteri or l i ghti ng i s turned on i n the dayl i ght, i t over-
ri des the sel ected panel di mmer swi tch si gnal by
sendi ng a message on the CCD bus to i l l umi nate al l
vacuum fl uorescent di spl ays at ful l bri ghtness for
easi er vi si bi l i ty i n dayti me l i ght l evel s. The auto-
mati c funeral mode or parade mode has no effect on
the i ncandescent bul b di mmi ng l evel s.
Refer to Group 8L - Lamps for more i nformati on.
The crui se-on i ndi cator l amp gi ves an i ndi cati on
when the vehi cl e speed control system i s turned on,
even when the system i s not currentl y engaged. The
l amp i s turned on by the i nstrument cl uster ci rcui try
for about four seconds when the i gni ti on swi tch i s
The PCM uses an i nput from the anal og resi stor-
mul ti pl exed vehi cl e speed control swi tches i n the
steeri ng wheel to deci de whether to turn the l amp on
or off. The PCM then sends the proper message to
the i nstrument cl uster on the CCD data bus. Refer to
Group 8H - Vehi cl e Speed Control System for more
i nformati on.
The headl amp hi gh beam i ndi cator l amp gi ves an
i ndi cati on when the headl amp hi gh beams are turned
on. The l amp i s turned on by the i nstrument cl uster
ci rcui try for about four seconds when the i gni ti on
recei ved from the Body Control Modul e (BCM) on the
The BCM uses an i nput from the headl amp di m-
mer (mul ti -functi on) swi tch to deci de whether the
headl amp hi gh beams are turned on. I t then sends
CCD data bus to turn the l amp on or off. Refer to
Group 8L - Lamps for more i nformati on.
The l ow fuel warni ng l amp gi ves an i ndi cati on
when the fuel l evel i n the fuel tank has fal l en bel ow
about one-ei ghth of a ful l tank, as regi stered on the
fuel gauge. The i nstrument cl uster ci rcui try l i ghts
the l amp for about four seconds when the i gni ti on
After the bul b test, the i nstrument cl uster ci rcui try
control s the l amp based upon a message recei ved
from the Body Control Modul e (BCM) on the
The BCM uses a fuel l evel message recei ved from
data bus to deci de when the fuel l evel i s l ow. The
BCM then sends the proper message to the i nstru-
ment cl uster on the CCD data bus to turn the l amp
on or off. When the l amp-on message i s sent, the
BCM al so i ssues a si ngl e l ow fuel warni ng chi me
tone. Once the l amp i s turned on, an i ncrease i n the
fuel l evel of at l east one-hal f gal l on i s requi red before
the PCM i nput to the BCM wi l l change and cause a
l amp-off message to be i ssued. I f the PCM detects a
short or open i n the fuel gauge sendi ng uni t ci rcui t,
i t sends a message on the CCD data bus that wi l l
cause the fuel gauge poi nter to move to the empty
stop and the l ow fuel l amp to be turned on.
The Check Engi ne or Mal functi on I ndi cator Lamp
(MI L) gi ves an i ndi cati on when the Powertrai n Con-
trol Modul e (PCM) has recorded a Di agnosti c Troubl e
Code (DTC) for an On-Board Di agnosti cs I I (OBDI I )
emi ssi ons-rel ated ci rcui t or component mal functi on.
recei ved from the PCM on the Chrysl er Col l i si on
The PCM uses i nputs from many emi ssi ons-rel ated
ci rcui ts and sensors, al ong wi th i ts i nternal program-
mi ng, to deci de whether a condi ti on exi sts that
requi res the MI L l amp to be turned on. The PCM
MI L l amp-on message from the PCM, i t sends a
chi me request message to the Body Control Modul e
(BCM) on the CCD data bus for a si ngl e chi me tone
to sound.
The MI L l amp can al so be used to di spl ay a stored
DTC by fl ashi ng on and off. Refer to Group 14 - Fuel
Systems for more i nformati on on the PCM or the
PCM i nputs. Refer to Group 25 - Emi ssi on Control
Systems for more i nformati on on DTCs and thei r
retri eval .
Vehi cl es sol d i n countri es where i t i s requi red
equi pment, have a master l i ghti ng i ndi cator l amp.
The master l i ghti ng i ndi cator l amp gi ves an i ndi ca-
ti on when the exteri or l amps are l i ghted. The l amp i s
hard-wi red i n the i nstrument cl uster, and i s com-
pl etel y control l ed by the panel l amps dri ver ci rcui t.
The l amp i s grounded at al l ti mes and recei ves a
Control Modul e (BCM). The i nstrument cl uster ci r-
cui try does not perform a bul b test for thi s l amp.
Refer to Cl uster I l l umi nati on Lamp i n thi s group, or
to Group 8L - Lamps for more i nformati on.
The seat bel t remi nder l amp gi ves a vi sual
remi nder to the vehi cl e occupants to fasten thei r seat
bel ts. The l amp i s turned on by the i nstrument cl us-
ter ci rcui try for about seven seconds when the i gni -
ti on swi tch i s turned to the On posi ti on. I f the dri ver
seat bel t swi tch i s cl osed (seat bel t i s not buckl ed),
the Body Control Modul e (BCM) wi l l al so sound a
chi me warni ng for the durati on of the seat bel t
remi nder l amp i l l umi nati on. The chi me warni ng wi l l
stop when the dri ver seat bel t swi tch i s open (seat
bel t i s buckl ed).
The seat bel t remi nder l amp al so serves as a
backup for the ai rbag i ndi cator l amp. Fol l owi ng the
seat bel t remi nder l amp seven second di spl ay func-
ti on, i f the i nstrument cl uster ci rcui try has detected
an i noperati ve ai rbag i ndi cator l amp ci rcui t i t wi l l
fl ash the seat bel t remi nder l amp on and off for
twenty seconds. I f the seat bel t remi nder l amp
fl ashes l onger than twenty seconds, or fl ashes at any
ti me other than i mmedi atel y after the i ni ti al seven
second seat bel t remi nder l amp di spl ay, i t i ndi cates
an ai rbag system faul t has been detected and that
the ai rbag i ndi cator l amp i s i noperati ve.
Refer to Group 8U - Chi me/Buzzer Warni ng Sys-
tems for more i nformati on.
The l eft and ri ght turn si gnal i ndi cator l amps gi ve
an i ndi cati on when the turn si gnal ci rcui ts are acti -
vated. These l amps are hard-wi red i n the i nstrument
cl uster, and are compl etel y control l ed by the turn si g-
nal and hazard warni ng (mul ti -functi on) swi tches.
The i ndi cator l amps are grounded at al l ti mes and
recei ve battery feed through the contacts of the
mul ti -functi on swi tch when the turn si gnal l ever
(mul ti -functi on swi tch stal k) or hazard warni ng but-
ton are actuated to the On posi ti on. The i nstrument
cl uster ci rcui try does not perform a bul b test of these
l amps. Refer to Group 8J - Turn Si gnal and Hazard
Warni ng Systems for more i nformati on.
Vehi cl es equi pped wi th a manual transmi ssi on
have an upshi ft i ndi cator l amp. The upshi ft i ndi cator
l amp gi ves an i ndi cati on when the dri ver shoul d shi ft
to the next hi ghest gear for the best fuel economy.
i nternal programmi ng to deci de whether the engi ne
speed and l oad condi ti ons are proper for a transmi s-
si on upshi ft. The PCM then sends the proper mes-
sage to the i nstrument cl uster on the CCD data bus
to turn the l amp on or off. The PCM wi l l send a
l amp-off message three to fi ve seconds after a
l amp-on message, i f an upshi ft i s not performed. The
l amp wi l l then remai n off unti l the vehi cl e stops
accel erati ng and i s brought back i nto the range of
l amp operati on, or unti l the transmi ssi on i s shi fted
i nto another gear. Refer to Group 14 - Fuel Systems
for more i nformati on on the PCM and the PCM
i nputs.
WAIT-TO-START LAMP
have a wai t-to-start l amp. The wai t-to-start l amp
gi ves an i ndi cati on that the condi ti ons for easi est
starti ng of the di esel engi ne have not yet been
achi eved. The l amp i s turned on by the i nstrument
cl uster ci rcui try for about four seconds when the
i gni ti on swi tch i s turned to the On posi ti on as a bul b
test. After the bul b test, the l amp i s control l ed by the
i nternal programmi ng to determi ne whether the
proper condi ti ons exi st for easi est di esel engi ne start-
i ng. The PCM then sends the proper message to the
more i nformati on on the PCM and the PCM i nputs.
WATER-IN-FUEL LAMP
have a water-i n-fuel l amp. The water-i n-fuel l amp
gi ves an i ndi cati on when the water contami nati on i n
the di esel fuel exceeds a certai n l evel . The l amp i s
turned on by the i nstrument cl uster ci rcui try for
about three seconds when the i gni ti on swi tch i s
The PCM uses an i nput from the water-i n-fuel sen-
sor i n the fuel fi l ter/water separator to determi ne
that excess water has accumul ated i n the di esel fuel .
The PCM then sends the proper message to the
more i nformati on.
INSTRUMENT CLUSTER
Al l of the gauges and most of the i ndi cator l amps
i n the i nstrument cl uster are control l ed by messages
recei ved by the i nstrument cl uster ci rcui try on the
CCD data bus. Onl y the cl uster i l l umi nati on l amps,
anti -l ock brake system l amp, turn si gnal i ndi cator
l amps, and the master l i ghti ng i ndi cator l amp (i f the
vehi cl e i s so equi pped) are hard-wi red i n the gauge
cl uster.
I f an i ndi vi dual gauge or l amp i s i noperati ve, see
the di agnosti c procedure under the headi ng for that
gauge or l amp. For ci rcui t descri pti ons and di agrams,
Wi ri ng Di agrams. I f more than one gauge or l amp i s
i noperati ve, perform the fol l owi ng:
BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT
SYSTEMS BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE. FAIL-
URE TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Check the fuse i n the juncti on bl ock modul e. I f
OK, go to Step 2. I f not OK, repl ace the faul ty fuse.
Remove the i nstrument cl uster bezel and the cl uster
cl uster wi re harness connector. I f OK, go to Step 4. I f
not OK, repai r the open ci rcui t from the fuse as
requi red.
Probe each ground ci rcui t cavi ty of the cl uster wi re
harness connector. Check for conti nui ty to a good
ground. There shoul d be conti nui ty. I f OK, refer to
further testi ng of the i nstrument cl uster ci rcui try
and the CCD data bus wi th a DRB scan tool . I f not
OK, repai r the open ci rcui t to ground as requi red.
wi th the gauge and not wi th cool i ng system perfor-
mance. The actual engi ne cool ant temperature shoul d
be checked wi th a test gauge or thermometer and
compared to the gauge readi ngs before you proceed
wi th gauge di agnosi s. Refer to Group 7 - Cool i ng Sys-
tem for more i nformati on. Refer to Group 8W - Wi r-
i ng Di agrams for ci rcui t descri pti ons and di agrams.
SYSTEMS BEFORE ATTEMPTING STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL COM-
PONENT DIAGNOSIS OR SERVICE. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
Di agnosi s of the cool ant temperature sensor and
ci rcui t or the Powertrai n Control Modul e (PCM)
shoul d be performed wi th the DRB scan tool as
dures manual . Di agnosi s of the cool ant temperature
gauge, the i nstrument cl uster ci rcui try, or the CCD
data bus shoul d be performed wi th the DRB scan tool
dures manual .
FUEL GAUGE
wi th the gauge or sendi ng uni t and not wi th the fuel
tank. I nspect the fuel tank for si gns of damage or
di storti on that coul d affect the sendi ng uni t perfor-
mance before you proceed wi th gauge di agnosi s.
Di agnosi s of the fuel gauge sendi ng uni t and ci r-
cui t or the Powertrai n Control Modul e (PCM) shoul d
the proper Powertrai n Di agnosti c Procedures man-
ual . Di agnosi s of the fuel gauge, the i nstrument cl us-
ter ci rcui try, or the CCD data bus shoul d be
performed wi th the DRB scan tool as descri bed i n the
Di agnosi s of the odometer and tri p odometer di spl ay,
the i nstrument cl uster ci rcui try, the Body Control
Modul e (BCM), or the CCD data bus shoul d be per-
OIL PRESSURE GAUGE
wi th the gauge and not wi th the engi ne oi l i ng system
performance. The actual engi ne oi l pressure shoul d
be checked wi th a test gauge and compared to the
i nstrument cl uster gauge readi ngs before you proceed
wi th gauge di agnosi s. Refer to Group 9 - Engi nes for
more i nformati on. Refer to Group 8W - Wi ri ng Di a-
Di agnosi s of the oi l pressure sensor and ci rcui t or
Di agnosi s of the oi l pressure gauge, the i nstrument
SPEEDOMETER
Di agnosi s of the speedometer, the i nstrument cl uster
ci rcui try, or the CCD data bus shoul d be performed
wi th the DRB scan tool as descri bed i n the proper
TACHOMETER
descri pti ons and di agrams. Di agnosi s of the crank-
shaft posi ti on sensor and ci rcui t or the Powertrai n
Control Modul e (PCM) shoul d be performed wi th the
DRB scan tool as descri bed i n the proper Powertrai n
Di agnosti c Procedures manual . Di agnosi s of the
tachometer, the i nstrument cl uster ci rcui try, or the
CCD data bus shoul d be performed wi th the DRB
Procedures manual .
VOLTMETER
accuracy, be certai n to confi rm proper chargi ng sys-
tem operati on before consi deri ng gauge repl acement.
mati on. Refer to Group 8W - Wi ri ng Di agrams for ci r-
cui t descri pti ons and di agrams.
Di agnosi s of the system vol tage i nput ci rcui t or the
Powertrai n Control Modul e (PCM) shoul d be per-
Di agnosi s of the vol tmeter gauge, the i nstrument
l amp condi ti on. I f the ai rbag i ndi cator l amp stays on
on and stays on whi l e dri vi ng, refer to Group 8M -
Passi ve Restrai nt Systems for di agnosi s. For ci rcui t
ment Cl uster, 8W-43 - Ai rbag System, and 8W-45 -
Body Control Modul e i n Group 8W - Wi ri ng Di a-
grams.
The ai rbag i ndi cator l amp has a l amp backup fea-
ture. Fol l owi ng the seat bel t remi nder l amp di spl ay
functi on, i f the i nstrument cl uster ci rcui try has
detected an i noperati ve ai rbag warni ng l amp ci rcui t
i t wi l l fl ash the seat bel t remi nder l amp on and off
for twenty seconds. Once the i nstrument cl uster ci r-
cui try has detected an i noperati ve ai rbag warni ng
l amp ci rcui t, i f a l amp-on message i s recei ved from
the Ai rbag Control Modul e (ACM) on the CCD data
bus, the seatbel t remi nder l amp wi l l fl ash for twel ve
seconds or the durati on of the ai rbag system mal -
functi on, whi chever i s l onger.
I f the ai rbag i ndi cator l amp fai l s to l i ght when the
i gni ti on swi tch i s turned to the On posi ti on, and the
seat bel t remi nder l amp fl ashes fol l owi ng i ts normal
di spl ay functi on (about seven seconds after the i gni -
ai rbag i ndi cator l amp bul b wi th a known good uni t.
I f the ai rbag i ndi cator l amp sti l l fai l s to operate,
di agnosi s of the l amp, the i nstrument cl uster ci r-
cui try, the CCD data bus, and the Body Control Mod-
ul e (BCM) shoul d be performed wi th a DRB scan tool
dures manual .
Anti -l ock Brake System (ABS) l amp condi ti on. I f the
ABS l amp stays on wi th the i gni ti on swi tch i n the
On posi ti on, or comes on and stays on whi l e dri vi ng,
refer to Group 5 - Brakes for di agnosi s. I f no ABS
probl em i s found, the fol l owi ng procedure wi l l hel p
l ocate a short or open i n the ABS l amp ci rcui t. For
I nstrument Cl uster, and 8W-35 - Al l -Wheel Anti -Lock
Brakes i n Group 8W - Wi ri ng Di agrams.
check for battery vol tage at the fuse i n the juncti on
cl uster assembl y.
battery vol tage between the fused i gni ti on swi tch
output ci rcui t and the ABS warni ng l amp dri ver ci r-
cui t cavi ti es of the cl uster wi re harness connector
wi thi n fi ve seconds of turni ng the i gni ti on swi tch to
the On posi ti on. I f OK, repl ace the faul ty bul b. I f not
OK, go to Step 5.
cabl e. Unpl ug the Control l er Anti -l ock Brake (CAB)
the ABS warni ng l amp dri ver ci rcui t cavi ty of the
cl uster wi re harness connector and a good ground.
(6) Check for conti nui ty between the ABS warni ng
l amp dri ver ci rcui t cavi ti es of the cl uster wi re har-
ness connector and the CAB wi re harness connector.
There shoul d be conti nui ty. I f OK, refer to Group 5 -
Brakes for di agnosi s of the CAB. I f not OK, repai r
BRAKE WARNING LAMP
brake warni ng l amp condi ti on. I f the brake warni ng
l amp stays on wi th the i gni ti on swi tch i n the On
posi ti on and the parki ng brake rel eased, or comes on
whi l e dri vi ng, refer to Group 5 - Brakes for di agnosi s.
I f no servi ce brake or parki ng brake probl em i s
found, proceed as fol l ows. Refer to 8W-40 - I nstru-
ment Cl uster, 8W-35 - Al l -Wheel Anti -Lock Brakes,
and 8W-45 - Body Control Modul e i n Group 8W -
grams.
I f the brake warni ng l amp fai l s to l i ght duri ng the
bul b test (for about four seconds after the i gni ti on
swi tch i s turned to the On posi ti on), repl ace the bul b
wi th a known good uni t. I f the l amp sti l l fai l s to
l i ght, di agnosi s of the park brake swi tch and ci rcui t,
the brake warni ng swi tch and ci rcui t, the Body Con-
trol Modul e (BCM), the i nstrument cl uster ci rcui try,
or the CCD data bus shoul d be performed wi th a
CHECK GAUGES LAMP
l amp condi ti on. I f the check gauges l amp stays on
on whi l e dri vi ng wi th no unusual gauge readi ngs evi -
dent, refer to the proper Body Di agnosti c Procedures
manual for di agnosi s. For ci rcui t descri pti ons and
di agrams, refer to 8W-30 - Fuel /I gni ti on Systems,
8W-40 - I nstrument Cl uster, and 8W-45 - Body Con-
trol Modul e i n Group 8W - Wi ri ng Di agrams.
I f the check gauges l amp fai l s to l i ght duri ng the
check gauges l amp bul b wi th a known good uni t. I f
the check gauges l amp sti l l fai l s to operate, di agnosi s
of the l amp, the i nstrument cl uster ci rcui try, the
CCD data bus, and the Body Control Modul e (BCM)
manual .
cl uster i l l umi nati on l amp condi ti on. I f the probl em
bei ng di agnosed i s rel ated to the di mmi ng l evel of
the cl uster i l l umi nati on l amps, di agnosi s shoul d be
I nstrument Cl uster, 8W-45 - Body Control Modul e,
and/or 8W-50 - Front Li ghti ng i n Group 8W - Wi ri ng
Di agrams.
I f onl y i ndi vi dual cl uster i l l umi nati on l amps are
i noperati ve, repl ace the faul ty bul bs. I f al l of the
cl uster i l l umi nati on l amps are i noperati ve, proceed
as fol l ows.
as requi red.
l amp condi ti on. I f the probl em bei ng di agnosed i s an
i naccurate crui se-on i ndi cator l amp, refer to Group
8H - Vehi cl e Speed Control and/or to the proper Pow-
ertrai n Di agnosti c Procedures manual for di agnosi s.
- Vehi cl e Speed Control and 8W-40 - I nstrument
Cl uster i n Group 8W - Wi ri ng Di agrams.
I f the crui se-on i ndi cator l amp fai l s to l i ght duri ng
crui se-on i ndi cator l amp bul b wi th a known good
uni t. I f the crui se-on l amp sti l l fai l s to operate, di ag-
nosi s of the l amp, the i nstrument cl uster ci rcui try,
and the CCD data bus shoul d be performed wi th a
nosti c Procedures manual . Di agnosi s of the speed
control swi tches and ci rcui ts and/or Powertrai n Con-
I f the probl em bei ng di agnosed i s rel ated to
Graphi c Di spl ay Modul e (GDM) i l l umi nati on, see the
GDM I l l umi nati on di agnosi s bel ow. I f the probl em
bei ng di agnosed i s rel ated to the four-wheel dri ve
di spl ay or four-wheel dri ve message l amps, see the
Four-Wheel Dri ve I ndi cator Lamp di agnosi s bel ow.
di agrams.
GDM ILLUMINATION
i l l umi nati on l amp condi ti on. I f the probl em bei ng
di agnosed i s rel ated to the di mmi ng l evel of the i l l u-
mi nati on l amps, di agnosi s shoul d be performed wi th
a DRB scan tool as descri bed i n the proper Body
I f onl y i ndi vi dual i l l umi nati on l amps are i nopera-
ti ve, repl ace the faul ty bul bs. I f al l of the i l l umi na-
ti on l amps are i noperati ve, proceed as fol l ows.
Unpl ug the GDM wi re harness connector and connect
the battery negati ve cabl e.
(2) Turn the park l amps on wi th the headl amp
swi tch. Adjust the panel l amp di mmer swi tch knob to
i ts hi ghest l evel (ful l y upwards). Check for vol tage at
the panel l amp dri ver ci rcui t cavi ty of the GDM wi re
harness connector. I f OK, repl ace the faul ty GDM. I f
not OK, go to Step 3.
GDM wi re harness connector and the BCM wi re har-
ness connector. I f OK, refer to Group 8L - Lamps for
di agnosi s of the headl amp swi tch and/or the proper
Body Di agnosti c Procedures manual for di agnosi s of
the BCM. I f not OK, repai r the open ci rcui t as
requi red.
FOUR-WHEEL DRIVE INDICATOR LAMP
faul ty swi tch.
Unpl ug the GDM wi re harness connector.
(4) Check the conti nui ty of the ci rcui t for the i ndi -
cator l amp or wheel l amp that i s not functi oni ng
between the GDM wi re harness connector and the
transfer case swi tch wi re harness connector. There
(5) Repl ace the bul b for the i noperati ve i ndi cator
l amp or wheel l amp. Pl ug i n the GDM and transfer
case wi re harness connectors. Connect the battery
negati ve cabl e and check the operati on of the i noper-
ati ve l amp. I f OK, di scard the faul ty bul b. I f not OK,
repl ace the faul ty GDM.
headl amp hi gh beam i ndi cator l amp condi ti on. I f the
probl em bei ng di agnosed i s rel ated to i noperati ve
headl amp hi gh beams, refer to Group 8L - Lamps for
di agnosi s of the headl amp system. For ci rcui t
I f the headl amp hi gh beam i ndi cator l amp fai l s to
l i ght duri ng the bul b test (about four seconds after
the i gni ti on swi tch i s turned to the On posi ti on),
repl ace the headl amp hi gh beam i ndi cator l amp bul b
wi th a known good uni t. I f the i ndi cator l amp sti l l
fai l s to operate, di agnosi s of the l amp, the i nstru-
ment cl uster ci rcui try, the CCD data bus, or the Body
Control Modul e (BCM) shoul d be performed wi th a
l ow fuel warni ng l amp condi ti on. I f the probl em
bei ng di agnosed i s rel ated to l amp accuracy, be cer-
tai n to confi rm the probl em i s the wi th the l ow fuel
warni ng l amp and not wi th the fuel gauge ci rcui t.
See the di agnosi s for the Fuel Gauge i n thi s group. I f
no fuel gauge probl em i s found, the fol l owi ng proce-
dure wi l l hel p to i denti fy a faul ty l ow fuel warni ng
l amp ci rcui t. For ci rcui t descri pti ons and di agrams,
Wi ri ng Di agrams.
I f the l ow fuel warni ng l amp fai l s to l i ght duri ng
swi tch i s turned to the On posi ti on), repl ace the l ow
fuel warni ng l amp bul b wi th a known good uni t. I f
the l amp, the i nstrument cl uster ci rcui try, the CCD
data bus, or the Body Control Modul e (BCM) shoul d
the proper Body Di agnosti c Procedures manual .
Di agnosi s of the fuel gauge sendi ng uni t and ci rcui t
or the Powertrai n Control Modul e (PCM) shoul d be
mal functi on i ndi cator (Check Engi ne) l amp condi ti on.
I f the l amp comes on and stays on wi th the engi ne
runni ng, refer to Group 14 - Fuel Systems for di ag-
nosi s. For ci rcui t descri pti ons and di agrams, refer to
8W-40 - I nstrument Cl uster i n Group 8W - Wi ri ng
Di agrams.
I f the mal functi on i ndi cator l amp fai l s to l i ght dur-
i ng the bul b test (about three seconds after the i gni -
mal functi on i ndi cator l amp bul b wi th a known good
uni t. I f the i ndi cator l amp sti l l fai l s to operate, di ag-
nosi s of the l amp, the i nstrument cl uster ci rcui try, or
the CCD data bus shoul d be performed wi th a DRB
Procedures manual . Di agnosi s of the Powertrai n Con-
The master l i ghti ng i ndi cator shares the same ci r-
cui try as the cl uster i l l umi nati on l amps, and wi l l
bri ghten and di m when the panel l amp di mmer
swi tch i s adjusted. The di agnosi s found here
addresses an i noperati ve master l i ghti ng i ndi cator
l amp condi ti on. I f the probl em bei ng di agnosed i s
rel ated to the di mmi ng l evel of the master l i ghti ng
i ndi cator l amp, di agnosi s shoul d be performed wi th a
and di agrams, refer to 8W-40 - I nstrument Cl uster,
8W-45 - Body Control Modul e, and/or 8W-50 - Front
I f onl y the master l i ghti ng i ndi cator l amp i s i nop-
erati ve, repl ace the faul ty bul b. I f al l of the cl uster
i l l umi nati on l amps are i noperati ve, proceed as fol -
l ows.
as requi red.
seat bel t remi nder l amp condi ti on. I f the l amp comes
on and fl ashes fol l owi ng i ts di spl ay functi on (for
about seven seconds after the i gni ti on swi tch i s
turned to the On posi ti on), refer to the di agnosi s for
the ai rbag i ndi cator l amp i n thi s group. For ci rcui t
I f the seat bel t remi nder l amp fai l s to l i ght duri ng
i ts di spl ay functi on, repl ace the seat bel t remi nder
l amp bul b wi th a known good uni t. I f the remi nder
l amp sti l l fai l s to operate, di agnosi s of the l amp, and
the i nstrument cl uster ci rcui try shoul d be performed
wi th a DRB scan tool as descri bed i n the proper Body
turn si gnal i ndi cator l amp condi ti on. For any other
turn si gnal probl em, refer to Group 8J - Turn Si gnal
and Hazard Warni ng Systems for di agnosi s. I f no
turn si gnal or hazard warni ng system probl em i s
found, the fol l owi ng procedure wi l l hel p l ocate a
short or open i n the i ndi cator l amp ci rcui t. For ci r-
I nstrument Cl uster and 8W-50 - Front Li ghti ng i n
cl uster assembl y as descri bed i n thi s group.
(2) Connect the battery negati ve cabl e. Acti vate
the hazard warni ng system by depressi ng the hazard
warni ng swi tch. Check for battery vol tage at the
i noperati ve (ri ght or l eft) turn si gnal i ndi cator l amp
ci rcui t cavi ty of the cl uster wi re harness connector.
There shoul d be a swi tchi ng (on and off) battery vol t-
age si gnal . I f OK, repl ace the faul ty (ri ght or l eft)
i ndi cator bul b. I f not OK, repai r the open ci rcui t to
the turn si gnal (mul ti -functi on) swi tch as requi red.
upshi ft i ndi cator l amp condi ti on. I f l amp accuracy i s
suspect, di agnosi s shoul d be performed wi th a DRB
and di agrams, refer to 8W-40 - I nstrument Cl uster i n
I f the upshi ft i ndi cator l amp fai l s to l i ght duri ng
the bul b test (about three seconds after the i gni ti on
upshi ft i ndi cator l amp bul b wi th a known good uni t.
I f the i ndi cator l amp sti l l fai l s to operate, di agnosi s
of the l amp, the i nstrument cl uster ci rcui try, or the
Procedures manual .
The Vehi cl e I nformati on Center (VI C) has a num-
ber of di spl ay functi ons and features. The di agnosi s
found here addresses onl y those VI C messages and
functi ons that are control l ed by hard-wi red i nputs. To
di agnose any i nternal l y control l ed VI C functi on or
feature, or any that are enabl ed by i nputs on the
CCD data bus network, use a DRB scan tool and the
proper Body Di agnosti c Procedures manual . Refer to
8W-46 - Message Center i n Group 8W - Wi ri ng Di a-
COOLANT LEVEL LOW/COOLANT SENSOR
BAD
wi th the l amp and sensor and not wi th the engi ne
cool ant l evel . The actual engi ne cool ant l evel shoul d
be checked before you proceed wi th l amp and sensor
di agnosi s. Refer to 8W-46 - Message Center i n Group
8W - Wi ri ng Di agrams for compl ete ci rcui t descri p-
ti ons and di agrams.
(1) Unpl ug the cool ant l evel sensor wi re harness
connector on the cool ant reserve bottl e. Check for
conti nui ty between the ground ci rcui t cavi ty of the
(2) Wi th the engi ne cool ant at the proper l evel ,
the cool ant l evel sensor. The resi stance shoul d be
3000 to 3500 ohms. I f OK, go to Step 3. I f not OK,
tor. Check for conti nui ty between the engi ne cool ant
l evel swi tch sense ci rcui t cavi ty of the VI C wi re har-
(4) Check for conti nui ty between the engi ne cool -
ant l evel swi tch sense ci rcui t cavi ti es of the VI C wi re
harness connector and the engi ne cool ant l evel sensor
requi red.
FOUR-WHEEL DRIVE DISPLAY AND
INDICATORS/SERVICE 4WD SWITCH
I f the probl em bei ng di agnosed i s rel ated to an
i ncorrect or no four-wheel dri ve di spl ay or i ndi cator
functi ons, be certai n to confi rm that the probl em i s
wi th the VI C modul e and transfer case swi tch ci r-
cui ts, and not wi th a Powertrai n Control Modul e
(PCM) wi th an i ncorrect Vehi cl e I denti fi cati on Num-
ber (VI N). Thi s condi ti on can onl y occur i f the ori gi -
nal PCM was repl aced wi th a uni t from another
vehi cl e. The VI C modul e uses the VI N message
recei ved on the CCD data bus from the PCM to
determi ne i f the vehi cl e i s equi pped wi th two-wheel
dri ve or four-wheel dri ve.
I f a four-wheel dri ve vehi cl e has a two-wheel dri ve
VI N entered i n the PCM, the VI C wi l l i gnore al l
transfer case swi tch i nputs. I f a two-wheel dri ve
vehi cl e has a four-wheel dri ve VI N entered i n the
PCM, the rear wheel s i n the VI C di spl ay wi l l not
l i ght. Use a DRB scan tool and the proper Power-
trai n Di agnosti c Procedures manual to confi rm the
VI N i n the PCM.
I n addi ti on, i t shoul d be noted that a VI C Servi ce
4WD Swi tch message on a two-wheel dri ve vehi cl e
can occur i f a short ci rcui t occurs i n the transfer case
swi tch ci rcui ts from the VI C modul e, i n combi nati on
wi th a PCM havi ng a four-wheel dri ve VI N. To l ocate
the short ci rcui t, start at Step 3 of the fol l owi ng di ag-
nosti c procedure. Two-wheel dri ve model s do have
the same VI C wi re harness provi si ons as four-wheel
dri ve model s.
faul ty swi tch.
tor.
(4) Locate two pai rs of wi re harness connectors
l ocated i n the wi re harness l eadi ng to the VI C mod-
ul e. The wi re harness connectors shoul d be taped
back to the harness. One pai r of connectors are bl ack
wi th a si ngl e cavi ty. The other pai r are red wi th two
cavi ti es. I f the vehi cl e has the Quadra-Trac 4WD
transfer case, onl y the red wi re harness connectors
shoul d be joi ned. I f the vehi cl e has the Command-
Trac or Sel ec-Trac 4WD transfer case, onl y the bl ack
wi re harness connectors shoul d be joi ned. I n al l
cases, onl y one pai r of wi re harness connectors
shoul d be joi ned. I f OK, go to Step 5. I f not OK, cor-
rect the wi re harness connecti ons as requi red.
(5) Refer to the VI C 4WD Di spl ay Characteri sti cs
chart (Fi g. 3). Check the conti nui ty of the ci rcui t for
the i ndi cator l amp or wheel l amp that i s not func-
ti oni ng between the VI C modul e wi re harness con-
nector and the transfer case swi tch wi re harness
connector. There shoul d be conti nui ty. I f OK, repl ace
the faul ty VI C modul e. I f not OK, repai r the open ci r-
cui t as requi red.
REAR LAMP FAILURE
Refer to the di agnosi s for the l amp outage modul e
i n Group 8L - Lamps to di agnose thi s feature of the
VI C modul e. Refer to 8W-46 - Message Center i n
TURN SIGNAL ON
Refer to Group 8J - Turn Si gnal and Hazard Warn-
i ng Systems for more i nformati on on thi s feature of
the VI C modul e. The VI C modul e uses i ts i nternal
programmi ng, and i nputs from the combi nati on
fl asher on the fused i gni ti on swi tch output (L5) ci r-
cui t, and a vehi cl e speed sensor (di stance) message
recei ved on the CCD data bus from the Powertrai n
Control Modul e to control thi s message.
I f testi ng of the L5 ci rcui t between the VI C modul e
wi re harness connector and the combi nati on fl asher
cavi ty i n the juncti on bl ock reveal s no probl em, use a
cedures manual to di agnose the VI C modul e and the
CCD data bus. Refer to 8W-46 - Message Center i n
WASHER LEVEL LOW/WASHER SENSOR BAD
wi th the l amp and sensor and not wi th the washer
fl ui d l evel . The actual fl ui d l evel shoul d be checked
before you proceed wi th l amp and sensor di agnosi s.
di agrams.
Fig. 3 VIC 4WD Display Characteristics
(1) Unpl ug the washer fl ui d l evel sensor wi re har-
ness connector on the washer reservoi r bottl e. Check
for conti nui ty between the ground ci rcui t cavi ty of
the wi re harness connector and a good ground. There
(2) Wi th the washer fl ui d at the proper l evel ,
the washer fl ui d l evel sensor. The resi stance shoul d
be 3000 to 3500 ohms. I f OK, go to Step 3. I f not OK,
tor. Check for conti nui ty between the washer fl ui d
l evel sense ci rcui t cavi ty of the VI C modul e wi re har-
(4) Check for conti nui ty between the washer fl ui d
l evel sense ci rcui t cavi ti es of the VI C modul e wi re
harness connector and the washer fl ui d l evel sensor
requi red.
WAIT-TO-START LAMP
wai t-to-start l amp condi ti on. I f l amp accuracy i s sus-
pect, di agnosi s shoul d be performed wi th a DRB scan
Procedures manual . For ci rcui t descri pti ons and di a-
I f the wai t-to-start l amp fai l s to l i ght duri ng the
bul b test (about four seconds after the i gni ti on swi tch
i s turned to the On posi ti on), repl ace the wai t-to-
start l amp bul b wi th a known good uni t. I f the l amp
sti l l fai l s to operate, di agnosi s of the l amp, the
i nstrument cl uster ci rcui try, or the CCD data bus
manual . Di agnosi s of the Powertrai n Control Modul e
(PCM) shoul d be performed wi th a DRB scan tool as
dures manual .
WATER-IN-FUEL LAMP
water-i n-fuel l amp condi ti on. I f the l amp comes on
and stays on wi th the i gni ti on swi tch i n the On posi -
ti on or whi l e dri vi ng, be certai n to check for excess
water accumul ati on i n the fuel fi l ter/water separator
before attempti ng further di agnosi s. Refer to Group
14 - Fuel Systems for di agnosi s and servi ce of the
water-i n-fuel sensor. For ci rcui t descri pti ons and di a-
I f the water-i n-fuel l amp fai l s to l i ght duri ng the
water-i n-fuel l amp bul b wi th a known good uni t. I f
the l amp, the i nstrument cl uster ci rcui try, or the
Procedures manual .
SERVICE PROCEDURES
The fol l owi ng fl ow charts descri be the procedures
to perform an i ni ti al set-up of the Vehi cl e I nforma-
ti on Center (VI C), and how to reset the VI C servi ce
remi nder or cl ock setti ngs.
VIC Initial Set-Up
VIC Reset
SWITCH POD BEZEL
Both swi tch pod bezel s are secured to the i nstru-
ment panel wi th spri ng cl i p retai ners and a l i ght
snap fi t. To remove the bezel from the i nstrument
panel , pry gentl y around the edges of the bezel usi ng
a tri m sti ck or other sui tabl e wi de fl at-bl aded tool . To
i nstal l the bezel , hol d i t i n posi ti on wi th one hand,
then push the bezel fi rml y i nto pl ace wi th the other
hand.
KNEE BLOCKER
cabl e.
thi s group.
panel (Fi g. 4).
panel .
bl aded tool , gentl y pry the edges of the knee bl ocker
away from the i nstrument panel at the snap cl i p
retai ner l ocati ons (Fi g. 4).
from the vehi cl e.
CLUSTER BEZEL
cabl e.
thi s group.
(3) Remove the ni ne screws that secure the cl uster
(4) Pul l the cl uster bezel rearward and move i t to
the outboard si de of the steeri ng wheel to remove i t
from the vehi cl e.
INSTRUMENT CLUSTER
group.
(2) Remove the two screws that secure each end of
the i nstrument cl uster to the i nstrument panel .
(3) Pul l the i nstrument cl uster rearward and
remove i t from the vehi cl e.
CLUSTER LENS, HOOD, AND MASK
group.
thi s group.
(3) Remove the tri p odometer reset knob by pul l i ng
i t off of the swi tch stem (Fi g. 6).
l ens to the cl uster hood and gentl y pul l the l ens
away from the hood.
hood to the cl uster ci rcui t and gauge housi ng and
gentl y pul l the hood away from the housi ng.
(6) Gentl y l i ft the gauge mask away from the
l ocati ng pi ns on the front of the cl uster ci rcui t and
gauge housi ng.
GAUGE
(1) Remove the cl uster l ens, hood, and mask as
(2) Remove the screws that secure the gauge(s)
from the rear of the cl uster ci rcui t and gauge housi ng
(Fi g. 7).
Fig. 6 Instrument Cluster Components
(3) Remove the gauge(s) from the front of the cl us-
ter ci rcui t and gauge housi ng.
CLUSTER BULB
thi s group.
(2) Remove the bul b and hol der from the rear of
the cl uster housi ng by turni ng the hol der counter-
cl ockwi se (Fi g. 8).
Fig. 7 Gauge Mounting Screws
Fig. 8 Cluster Bulb Locations
(3) Unpl ug the bul b from the hol der.
CAUTION: Always use the correct bulb size and type
for replacement. An incorrect bulb size or type may
overheat and cause damage to the instrument clus-
ter printed circuit and/or the gauges.
OUTBOARD SWITCH POD
group.
(2) Remove the two screws that secure the out-
board swi tch pod to the i nstrument panel (Fi g. 9).
(3) Pul l the outboard swi tch pod out from the
ness connectors.
(4) Remove the outboard swi tch pod from the
i nstrument panel .
INBOARD SWITCH POD
cabl e.
(2) Remove the i nboard swi tch pod bezel as
i nboard swi tch pod to the i nstrument panel (Fi g. 10).
ness connectors.
i nstrument panel .
BODY CONTROL MODULE
(2) Remove the four screws bel ow the outboard
swi tch pod that secure the Body Control Modul e
(BCM) to the i nstrument panel armature (Fi g. 11).
(3) Move the BCM towards the steeri ng col umn far
enough to unpl ug the three wi re harness connectors.
(4) Remove the BCM from the i nstrument panel .
NOTE: If a new Body Control Module is installed, the
programmable features must be enabled and/or dis-
abled to the customers preferred settings. Use a
Fig. 9 Outboard Switch Pod Remove/Install
GLOVE BOX MODULE
(2) Remove the two screws that secure the top of
the i nstrument panel center bezel to the i nstrument
panel above the Graphi c Di spl ay Modul e (GDM) or
Vehi cl e I nformati on Center (VI C).
(3) Remove the ash recei ver from the i nstrument
panel center bezel .
(4) Remove the two screws i n the back of the ash
recei ver openi ng that secure the i nstrument panel
center bezel to the i nstrument panel armature.
(5) Remove the screw that secures the courtesy
l amp l ocated under the outboard end of the gl ove box
modul e.
(6) Open the passenger si de front door and remove
the screw that secures the outboard end of the gl ove
box modul e.
box hi nge to the i nstrument panel armature on the
l ower edge of the gl ove box modul e.
(8) Open the gl ove box door and remove the four
screws at the top of the gl ove box openi ng that secure
the upper edge of the gl ove box modul e to the i nstru-
ment panel armature.
(9) Lower the gl ove box modul e far enough to
unpl ug the wi re harness connectors from the gl ove
box l amp and swi tch, the ci gar l i ghter and l amp, and
the power outl et. Al so remove the ash recei ver l amp
bul b and socket as a uni t by gentl y pul l i ng i t out of
the ash recei ver l amp hood.
(10) Remove the gl ove box modul e from the vehi -
cl e.
INFORMATION CENTER
thi s group.
Graphi c Di spl ay Modul e (GDM) or Vehi cl e I nforma-
ti on Center (VI C) to the i nstrument panel armature
(Fi g. 12).
(3) Pul l the GDM or VI C uni t out from the i nstru-
ment panel far enough to unpl ug the wi re harness
connector.
(4) Remove the GDM or VI C from the i nstrument
panel .
Fig. 11 Body Control Module Remove/Install
Fig. 12 Graphic Display Module and Vehicle
Information Center Remove/Install
GLOVE BOX LAMP AND SWITCH
thi s group.
(2) From the back si de of the gl ove box modul e,
squeeze the retai ni ng tabs on the gl ove box l amp and
swi tch housi ng together and push the uni t out the
front of the modul e through the mounti ng hol e (Fi g.
13).
(3) To i nstal l the gl ove box l amp and swi tch uni t,
i nsert the uni t through the mounti ng hol e from the
front of the gl ove box modul e and push i n on the uni t
fi rml y, unti l the retai ni ng tabs snap i nto pl ace.
GLOVE BOX LATCH STRIKER
thi s group.
(2) From the top of the gl ove box modul e,
strai ghten the two mounti ng tabs that secure the
stri ker to the modul e (Fi g. 14).
(3) Pul l the l atch stri ker out from the upper gl ove
box openi ng.
(4) To i nstal l the l atch stri ker, i nsert the mounti ng
tabs through the sl ots i n the upper gl ove box openi ng
and bend the tabs over from the top of the gl ove box
modul e.
CIGAR LIGHTER
cabl e.
(2) Pul l the ci gar l i ghter knob and el ement out of
the ci gar l i ghter base.
(3) Look i nsi de the ci gar l i ghter base and note the
posi ti on of the retai ni ng bosses that secure the uni t
to the l i ght ri ng/retai ner i n the i nstrument panel
center bezel (Fi g. 15).
(4) I nsert a pai r of external snap ri ng pl i ers i nto
the ci gar l i ghter base and engage the ti ps of the pl i -
ers wi th the retai ni ng bosses.
(5) Squeeze the pl i ers to di sengage the retai ni ng
bosses from the base, and usi ng a gentl e rocki ng
moti on pul l the pl i ers and the ci gar l i ghter base out
of the l i ght ri ng/retai ner.
(6) Remove the pl i ers from the ci gar l i ghter base
and unpl ug the wi re harness connector.
(7) Remove the ci gar l i ghter l i ght ri ng/retai ner
from the i nstrument panel center bezel and unpl ug
the wi re harness connector.
Fig. 13 Glove Box Lamp and Switch Remove/Install
Fig. 14 Glove Box Latch Striker Remove/Install
POWER OUTLET
thi s group.
(2) From the rear of the i nstrument panel center
bezel , unscrew the power outl et shel l cl amp from the
power outl et base.
(3) Remove the power outl et base from the front of
the i nstrument panel center bezel .
POWER OUTLET DOOR
(1) I nsert a wi de fl at-bl aded tool such as a tri m
sti ck between the si de of the power outl et housi ng i n
the i nstrument panel center bezel and the upper
pi vot area of the power outl et door.
(2) Pry gentl y agai nst the upper pi vot area of the
power outl et door unti l the door pi vot pi n cl ears the
pi vot receptacl e i n the i nstrument panel center bezel .
(3) Pul l the power outl et door out of the power out-
l et housi ng.
(4) To i nstal l the door, i nsert one of the pi vot pi ns
i nto a pi vot receptacl e i n the center bezel and twi st
the door gentl y unti l the pi vot pi n on the opposi te
si de of the door snaps i nto the other pi vot receptacl e.
INSTRUMENT PANEL CENTER BEZEL
thi s group.
(2) Remove the two screws that secure the i nstru-
ment panel center bezel to the i nboard end of the
gl ove box modul e from the back si de of the gl ove box
modul e (Fi g. 16).
GLOVE BOX
Fig. 15 Cigar Lighter Remove/Install
Fig. 16 Instrument Panel Center Bezel Remove/
Install
cabl e.
(2) Dri l l out the two ri vets that secure the gl ove
box hi nge to the l ower edge of the gl ove box modul e
(Fi g. 17).
NOTE: The rivets are used to ease assembly during
the manufacturing process, but do not require
replacement following service.
box hi nge to the i nstrument panel armature.
(4) Rel ease the gl ove box l atch and remove the
gl ove box from the gl ove box modul e.
GLOVE BOX COMPONENTS
The gl ove box bezel i s the onl y component of the
gl ove box that can be servi ced wi thout gl ove box
removal . Al l other components wi l l requi re that the
gl ove box be removed from the gl ove box modul e as
GLOVE BOX BEZEL
(1) Open the gl ove box.
(2) Remove the two screws that secure the bezel at
the top of the gl ove box i nner door panel (Fi g. 18).
(3) Careful l y pry the bezel away from the outsi de
of the gl ove box door. There i s doubl e-faced adhesi ve
tape between the bezel and the outer door panel .
GLOVE BOX HINGE
group.
(2) Remove the screws that secure the gl ove box
hi nge to the gl ove box i nner door panel .
(3) Remove the gl ove box hi nge.
GLOVE BOX BIN
group.
(2) Remove the gl ove box hi nge as descri bed i n
thi s group.
(3) Remove the screws that secure each si de of the
bi n to the gl ove box door.
(4) Remove the gl ove box bi n.
GLOVE BOX LATCH AND HANDLE
group.
(2) Remove the gl ove box hi nge and gl ove box bi n
(3) Remove the two bezel screws, two l atch screws,
and one handl e screw from the gl ove box i nner door
panel .
(4) Remove the i nner door panel from the gl ove
box door.
(5) Remove the second gl ove box l atch handl e
screw (Fi g. 19).
(6) Remove the l atch and handl e from the gl ove
box door as a uni t.
GLOVE BOX LOCK CYLINDER
(1) Remove the gl ove box l atch and handl e as
(2) I nsert the key i nto the gl ove box l ock cyl i nder.
Fig. 17 Glove Box Remove/Install
Fig. 18 Glove Box Components
Fig. 19 Glove Box Latch and Handle Remove/Install
(3) I nsert a smal l screwdri ver i nto the retai ni ng
tumbl er rel ease sl ot and depress the retai ni ng tum-
bl er (Fi g. 20).
(4) Pul l the l ock cyl i nder out of the l atch handl e by
usi ng a gentl e twi sti ng and pul l i ng acti on on the key.
COWL TOP TRIM PANEL
cabl e.
(3) Pul l the panel up far enough to unpl ug the
wi re harness connector for the sol ar sensor, or to
remove the sol ar sensor from the cowl top tri m, i f the
vehi cl e i s so equi pped.
cl e.
INSTRUMENT PANEL TOP PAD
cabl e.
(2) Remove both swi tch pod bezel s, the cl uster
bezel , the knee bl ocker, the gl ove box modul e, and
the cowl top tri m panel . See the procedures i n thi s
group.
that secures the auto headl amp l i ght sensor/vehi cl e
theft securi ty system l amp near the defroster duct
outl et and move i t for cl earance of the i nstrument
panel top pad.
(4) Remove the screws around the peri meter of the
i nstrument panel top pad that secure the top pad to
the i nstrument panel armature.
(5) Li ft the top pad off of the i nstrument panel
armature and remove i t from the vehi cl e.
JUNCTION BLOCK
cabl e.
Fig. 20 Glove Box Lock Cylinder Remove/Install
22).
tri m.
(6) Unpl ug al l of the wi re harness connectors from
the juncti on bl ock cavi ti es.
(7) Remove the bol t that secures the juncti on bl ock
to the cowl si de panel (Fi g. 23).
(8) On Left-Hand Dri ve (LHD) model s onl y, l i ft
upwards on the juncti on bl ock to remove i ts sl i de-tab
mount off of the mounti ng bracket on the ri ght cowl
si de panel .
(9) Remove the juncti on bl ock from the vehi cl e.
INSTRUMENT PANEL ASSEMBLY
cabl e.
thi s group.
(3) Remove the knee bl ocker as descri bed i n thi s
group.
(4) Remove the bol ts that secure the l ower i nstru-
ment panel rei nforcement to the i nstrument panel
armature and remove the rei nforcement (Fi g. 24).
shrouds. Refer to Group 19 - Steeri ng for the proce-
dures.
(6) Unpl ug al l of the wi re harness connectors on
the steeri ng col umn-mounted components and
swi tches.
(7) Remove the three nuts that secure the steeri ng
col umn toe pl ate at the base of the steeri ng col umn.
(8) Remove the two nuts that secure the steeri ng
col umn mounti ng bracket to the studs on the steer-
i ng col umn and brake pedal support. Lower the
steeri ng col umn to the fl oor.
(9) Remove both cowl si de tri m panel s. Refer to
(10) Unpl ug the i nstrument panel to body wi re
harness connector under the l eft end of the i nstru-
ment panel .
(11) Unpl ug the brake l amp swi tch wi re harness
connector.
(12) Unpl ug the i nstrument panel to heater-A/C
housi ng vacuum harness connector (manual temper-
ature control onl y) and wi re harness connector
l ocated under the passenger si de end of the i nstru-
ment panel .
(13) Unpl ug the radi o antenna coaxi al cabl e con-
nector near the ri ght cowl si de panel .
Fig. 23 Junction Block Remove/Install
(14) Unpl ug al l of the i nstrument panel wi re har-
ness connectors from the juncti on bl ock on the ri ght
cowl si de panel .
(15) I f the vehi cl e i s so equi pped, di sconnect the
i n-car temperature sensor aspi rator hose at the cou-
pl i ng near the passenger si de of the transmi ssi on
fl oor tunnel .
(16) On Left-Hand Dri ve (LHD) model s onl y,
remove the ash recei ver and remove the screw i n the
back of the ash recei ver housi ng that secures the
i nstrument panel armature to the heater-A/C hous-
i ng.
(17) Pul l back the fl oor carpet on the transmi ssi on
fl oor tunnel from the base of the i nstrument panel
center bezel and remove the two bol ts that secure the
i nstrument panel center bracket to the fl oor.
(18) Remove the two bol ts that secure the i nstru-
ment panel center bracket to the dri ver si de of the
transmi ssi on fl oor tunnel .
(19) Remove the bol t that secures the i nstrument
panel armature to the steeri ng col umn and brake
pedal support.
the i nstrument panel armature to the cowl si de pan-
el s.
(21) Remove the cowl top tri m panel as descri bed
i n thi s group.
the i nstrument panel armature to the wi ndshi el d
fence.
(23) Remove the four nuts that secure the top of
the i nstrument panel armature to the studs on the
wi ndshi el d fence.
(24) Wi th the ai d of an assi stant, l i ft the i nstru-
ment panel off of the wi ndshi el d fence studs and
maneuver the assembl y out of the vehi cl e through
the passenger si de front door.
I nstrument panel center bracket to fl oor pan
transmi ssi on tunnel fasteners - 28 Nm (250 i n. l bs.)
I nstrument panel to wi ndshi el d fence bol ts and
nuts - 12 Nm (105 i n. l bs.)
I nstrument panel to cowl si de panel bol ts - 12
Nm (105 i n. l bs.)
I nstrument panel to steeri ng col umn support
bol t - 12 Nm (105 i n. l bs.)
Knee bl ocker mounti ng screws - 2.2 Nm (20 i n.
l bs.).
Fig. 24 Instrument Panel Assembly Remove/Install
AUDIO SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
ANTENNA RELAY . . . . . . . . . . . . . . . . . . . . . . . 3
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . 3
RADIO NOISE SUPPRESSION . . . . . . . . . . . . . . 4
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOTE RADIO SWITCH . . . . . . . . . . . . . . . . . 2
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ANTENNA RELAY . . . . . . . . . . . . . . . . . . . . . . . 9
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4
RADIO FREQUENCY INTERFERENCE . . . . . . 10
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE RADIO SWITCH . . . . . . . . . . . . . . . . . 6
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
ANTITHEFT SECURITY CODE . . . . . . . . . . . . . 10
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ANTENNA RELAY . . . . . . . . . . . . . . . . . . . . . . 17
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOTE RADIO SWITCH . . . . . . . . . . . . . . . . 11
SOUND BAR . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
GENERAL INFORMATION
INTRODUCTION
Fol l owi ng are general descri pti ons of the major
components used i n both the standard and opti onal
factory-i nstal l ed audi o systems. Refer to 8W-47 Audi o
System i n Group 8W - Wi ri ng Di agrams for compl ete
ci rcui t descri pti ons and di agrams.
MEMORY SYSTEM
An el ectroni c memory system i s an avai l abl e opti on
on thi s model . The memory system i s abl e to store
and recal l the dri ver si de power seat posi ti ons
(i ncl udi ng power l umbar and recl i ner posi ti ons), and
both outsi de power mi rror posi ti ons for two dri vers.
For vehi cl es wi th a radi o connected to the Chrysl er
Col l i si on Detecti on (CCD) data bus network, the
memory system i s al so abl e to store and recal l ten
radi o stati on presets (i ncl udi ng l ast stati on tuned) for
two dri vers. The memory system wi l l automati cal l y
return to al l of these setti ngs when the correspond-
i ng button (Dri ver 1 or 2) of the memory swi tch on
the dri ver si de front door tri m panel i s depressed, or
when the doors are unl ocked usi ng the correspondi ng
(Dri ver 1 or 2) Remote Keyl ess Entry (RKE) trans-
mi tter.
The Dri ver Door Modul e (DDM) recei ves hard-
wi red i nput from the memory set/sel ect swi tch on the
dri ver si de front door tri m panel . The DDM al so
recei ves messages on the CCD data bus from the
RKE recei ver i n the Passenger Door Modul e (PDM)
for the memory sel ect functi on. The DDM processes
these i nputs and sends messages to the PDM, the
Memory Seat Modul e (MSM), and the radi o (i f CCD
data bus capabl e) on the CCD data bus for memory
recal l .
Thi s group covers onl y the conventi onal di agnosti c
procedures for the audi o system components. For
di agnosi s of the memory system, use of a DRB scan
tool and the proper Body Di agnosti c Procedures man-
ual are recommended. For addi ti onal i nformati on on
the features and functi ons of the memory system,
refer to the vehi cl e owners manual .
ZG AUDIO SYSTEMS 8F - 1
RADIO
Factory-i nstal l ed recei ver avai l abi l i ty for thi s
model i s affected by the country for whi ch the vehi cl e
i s manufactured. Avai l abl e factory-i nstal l ed radi o
recei vers for vehi cl es desti ned for sal e i n North
Ameri ca i ncl ude an AM/FM/cassette (RAS sal es
code), an AM/FM/cassette/5-band graphi c equal i zer
wi th CD changer control feature (RBN sal es code), or
an AM/FM/CD/cassette/3-band graphi c equal i zer
(RAZ sal es code).
Avai l abl e factory-i nstal l ed radi o recei vers for vehi -
cl es desti ned for sal e outsi de North Ameri ca i ncl ude
an FM/MW/LW/cassette wi th RDS traffi c i nformati on
and anti theft features (RBL sal es code), an AM/FM/
cassette/5-band graphi c equal i zer wi th CD changer
control feature (RBN sal es code), an AM/FM/cassette
wi th CD changer control feature (RBA sal es code), or
an AM/FM/cassette wi th CD changer control feature
(RBJ sal es code).
Al l factory-i nstal l ed radi o recei vers are stereo El ec-
troni cal l y Tuned Radi os (ETR) and i ncl ude an el ec-
troni c di gi tal cl ock functi on.
Al l factory-i nstal l ed radi o recei vers for vehi cl es
desti ned for sal e i n North Ameri ca, except the RAS
model , communi cate on the Chrysl er Col l i si on Detec-
ti on (CCD) data bus network through a separate two-
way wi re harness connector. The CCD data bus
network al l ows the shari ng of sensor i nformati on.
Thi s hel ps to reduce wi re harness compl exi ty, i nter-
nal control l er hardware, and component sensor cur-
rent l oads. At the same ti me, thi s system provi des
i ncreased rel i abi l i ty, enhanced di agnosti cs, and
al l ows the addi ti on of many new feature capabi l i ti es.
Radi os connected to the CCD data bus network i n
vehi cl es equi pped wi th the opti onal Vehi cl e I nforma-
ti on Center (VI C) have a cl ock synchroni zati on fea-
ture. The VI C cl ock di spl ay i s automati cal l y updated
to the setti ng shown on the radi o cl ock through a
message sent on the CCD data bus by the radi o.
Refer to Group 8E - I nstrument Panel Systems for
more i nformati on on the VI C modul e.
I n addi ti on, radi os connected to the CCD data bus
have several audi o system functi ons that can be di ag-
nosed usi ng a DRB scan tool . Refer to the proper
Di agnosti c Procedures manual for more i nformati on
on DRB testi ng of the audi o systems.
For more i nformati on on radi o features, setti ng
procedures, and control functi ons refer to the owners
manual i n the vehi cl e gl ove box.
REMOTE RADIO SWITCH
A remote radi o control swi tch opti on i s avai l abl e on
Grand Cherokee Li mi ted model s sol d i n North Amer-
i ca wi th the AM/FM/cassette/5-band graphi c equal -
i zer (RBN sal es code) wi th CD changer control
feature, or the AM/FM/CD/cassette/3-band graphi c
equal i zer (RAZ sal es code) radi o recei vers. Two rock-
er-type swi tches are mounted on the back (i nstru-
ment panel si de) of the steeri ng wheel spokes. The
swi tch on the l eft spoke i s the seek swi tch and has
seek up, seek down, and preset stati on advance func-
ti ons. The swi tch on the ri ght spoke i s the vol ume
control swi tch and has vol ume up, and vol ume down
functi ons.
These swi tches are resi stor mul ti pl exed uni ts that
are hard-wi red to the Body Control Modul e (BCM)
through the cl ockspri ng. The BCM sends the proper
messages on the Chrysl er Col l i si on Detecti on (CCD)
data bus network to the radi o recei ver. For di agnosi s
of the BCM or the CCD data bus, refer to the proper
Body Di agnosti c Procedures manual . For more i nfor-
mati on on the operati on of the remote radi o swi tch
control s, refer to the owners manual i n the vehi cl e
gl ove box.
BODY CONTROL MODULE
One of the functi ons and features that the BCM
supports and control s, i s the remote radi o swi tches
on vehi cl es so equi pped. The BCM recei ves hard-
wi red resi stor mul ti pl exed i nputs from the remote
radi o swi tches. The programmi ng i n the BCM al l ows
i t to process those i nputs and send the proper mes-
sages to the radi o over the CCD data bus to control
the radi o vol ume, stati on seek, and preset stati on
advance functi ons.
outboard swi tch pod. Refer to Group 8E - I nstrument
Panel Systems for the removal and i nstal l ati on pro-
cedures. For di agnosi s of the BCM or the CCD data
bus, refer to the proper Body Di agnosti c Procedures
manual . The BCM can onl y be servi ced by an autho-
ri zed el ectroni c repai r stati on. Refer to the l atest
Warranty Pol i ci es and Procedures manual for a cur-
rent l i sti ng of authori zed el ectroni c repai r stati ons.
8F - 2 AUDIO SYSTEMS ZG
IGNITION-OFF DRAW FUSE
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse that i s removed when the vehi cl e i s
shi pped from the factory. Thi s fuse feeds vari ous
accessori es that requi re battery current when the
i gni ti on swi tch i s i n the Off posi ti on, i ncl udi ng the
cl ock and radi o stati on preset memory functi ons. The
fuse i s removed to prevent battery di scharge duri ng
vehi cl e storage.
When removi ng or i nstal l i ng the I OD fuse, i t i s
i mportant that the i gni ti on swi tch be i n the Off posi -
ti on. Fai l ure to pl ace the i gni ti on swi tch i n the Off
posi ti on can cause the radi o di spl ay to become scram-
bl ed when the I OD fuse i s removed and repl aced.
Removi ng and repl aci ng the I OD fuse agai n, wi th the
i gni ti on swi tch i n the Off posi ti on, wi l l correct the
scrambl ed di spl ay condi ti on.
The I OD fuse shoul d be checked i f the radi o stati on
preset memory or cl ock functi ons are errati c or i nop-
erati ve. The I OD fuse i s l ocated i n the Power Di stri -
buti on Center (PDC). Refer to the PDC l abel for I OD
fuse i denti fi cati on and l ocati on.
SPEAKER
The onl y speaker system offered wi th the base
AM/FM/cassette radi o recei ver (RAS sal es code)
i ncl udes four ful l -range speakers, one mounted i n
each of the four doors. Thi s i s al so the standard
equi pment speaker system offered wi th the AM/FM/
CD/cassette/3-band graphi c equal i zer (RAZ sal es
code).
Opti onal for the RAZ sal es code radi o, and stan-
dard for al l other radi os (except RAS sal es code) i s
the I nfi ni ty Gol d premi um speaker and 120 watt
ampl i fi er package. Thi s package uses an I nfi ni ty
ampl i fi er mounted on the fl oor beneath the rear seat
cushi on on the dri ver si de of the vehi cl e. The package
i ncl udes an I nfi ni ty coaxi al ful l -range speaker
mounted i n each rear door, an I nfi ni ty mi d-range
speaker mounted i n each front door, and an I nfi ni ty
tweeter mounted at each outboard end of the i nstru-
ment panel top cover.
The standard equi pment speaker system for the
Li mi ted Pl us package i s the I nfi ni ty Gol d premi um
speaker and 180 watt ampl i fi er package. I n addi ti on
to the i ncreased ampl i fi er output, thi s package adds
a sound bar mounted on the i nsi de roof headl i ner,
just forward of the l i ftgate openi ng. Thi s package
uses the same I nfi ni ty speakers as the 120 watt
ampl i fi er package i n the front doors and the i nstru-
ment panel , but uses I nfi ni ty woofers i n the rear
doors. I n addi ti on, the sound bar houses two I nfi ni ty
woofers and two I nfi ni ty tweeters, for a total of ten
system speakers.
ANTENNA
Antenna avai l abi l i ty i s affected by the country for
whi ch the vehi cl e i s manufactured. Al l model s bui l t
for sal e i n North Ameri ca use a fi xed-l ength stai nl ess
steel rod-type antenna mast. Model s bui l t for sal e
outsi de North Ameri ca use a power-operated tel e-
scopi ng-type antenna, extended and retracted by a
reversi bl e el ectri c motor. Ei ther antenna type i s
mounted on the ri ght front fender of the vehi cl e. The
antenna mast i s connected to the center wi re of the
coaxi al antenna cabl e, and i s not grounded to any
part of the vehi cl e.
To el i mi nate stati c, the antenna base must have a
good ground. The coaxi al antenna cabl e shi el d (the
outer wi re mesh of the cabl e) i s grounded to the
antenna base and the radi o chassi s.
The antenna coaxi al cabl e has an addi ti onal di s-
connect, l ocated near the ri ght end of the i nstrument
panel at the ri ght cowl si de panel . Thi s addi ti onal
di sconnect al l ows the i nstrument panel assembl y to
be removed and i nstal l ed wi thout removi ng the radi o.
The power antenna i s desi gned to rai se automati -
cal l y when both the i gni ti on swi tch and the radi o are
turned on. When the i gni ti on swi tch i s turned to the
Off posi ti on, the antenna wi l l automati cal l y retract.
When the i gni ti on swi tch i s turned to the On posi ti on
and the radi o i s turned off, the antenna wi l l remai n
i n i ts retracted posi ti on.
The power antenna i s control l ed by a combi nati on
of an external power antenna rel ay l ocated i n the
juncti on bl ock, and two l i mi t swi tches that are bui l t
i nto the antenna motor housi ng. There i s a gear-op-
erated cam system to acti vate the l i mi t swi tches. The
l i mi t swi tches are used to open the motor ci rcui ts
when the antenna mast reaches i ts ful l y-extended or
ful l y-retracted posi ti ons.
When the radi o or i gni ti on swi tch i s turned off, the
power antenna rel ay coi l i s de-energi zed. Wi th the
coi l de-energi zed, battery vol tage swi tches to the
motor through the cl osed l ower l i mi t swi tch. The
antenna then retracts unti l the l ower l i mi t swi tch
opens. The antenna cannot be adjusted to an i nter-
medi ate posi ti on. I t must be ful l y-extended or ful l y-
retracted. The power antenna uni t cannot be
repai red and, i f faul ty or damaged, the enti re assem-
bl y must be repl aced.
The factory-i nstal l ed El ectroni cal l y Tuned Radi os
(ETRs) automati cal l y compensate for radi o antenna
tri m. Therefore, no antenna tri mmer adjustment i s
requi red or possi bl e when repl aci ng the recei ver or
the antenna.
ANTENNA RELAY
The antenna rel ay i s a I nternati onal Standards
Organi zati on (I SO)-type rel ay. The antenna rel ay i s a
el ectromechani cal devi ce that swi tches battery cur-
rent and ground to the proper brushes of the revers-
i bl e power antenna motor when the i gni ti on swi tch
and radi o swi tch are turned to the On or Off posi -
ti ons. 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
antenna rel ay.
The antenna rel ay i s l ocated i n the juncti on bl ock
on the ri ght cowl si de panel , under the i nstrument
panel i n the passenger compartment.
The antenna rel ay cannot be repai red and, i f faul ty
RADIO NOISE SUPPRESSION
Radi o Frequency I nterference (RFI ) and El ectro-
Magneti c I nterference (EMI ) noi se suppressi on i s
accompl i shed pri mari l y through ci rcui try i nternal to
the radi o recei vers. These i nternal suppressi on
devi ces are onl y servi ced as part of the radi o recei ver.
External suppressi on devi ces that are servi ced, and
shoul d be checked i n the case of RFI or EMI noi se
compl ai nts, i ncl ude the fol l owi ng:
Radi o antenna base ground
Radi o chassi s ground wi re, strap, or bracket
Engi ne-to-body ground strap (i f the vehi cl e i s so
equi pped)
Cab-to-bed ground strap (i f the vehi cl e i s so
equi pped)
Heater core ground strap (i f the vehi cl e i s so
equi pped)
Resi stor-type spark pl ugs
Radi o suppressi on-type secondary i gni ti on wi r-
i ng.
I n addi ti on, i f the source of RFI or EMI noi se i s
i denti fi ed as a component on the vehi cl e (i .e., gener-
ator, bl ower motor, etc.), the ground path for that
component shoul d be checked. I f excessi ve resi stance
i s found i n that ci rcui t, repai r that ci rcui t as
requi red before consi deri ng any component repl ace-
ment.
I f the source of the noi se i s i denti fi ed as two-way
mobi l e radi o or tel ephone equi pment, check the
equi pment i nstal l ati on for the fol l owi ng:
Power connecti ons shoul d be made di rectl y to
the battery, and fused as cl osel y to the battery as
possi bl e.
The antenna shoul d be mounted on the roof or
toward the rear of the vehi cl e. Remember that mag-
neti c antenna mounts on the roof panel can adversel y
affect the operati on of an overhead consol e compass,
i f the vehi cl e i s so equi pped.
The antenna cabl e shoul d be ful l y shi el ded coax-
i al cabl e, shoul d be as short as i s practi cal , and
shoul d be routed away from the factory-i nstal l ed
vehi cl e wi re harnesses whenever possi bl e.
The antenna and cabl e must be careful l y
matched to ensure a l ow Standi ng Wave Rati o
(SWR).
Fl eet vehi cl es are avai l abl e wi th an extra-cost RFI -
suppressed Powertrai n Control Modul e (PCM). Thi s
uni t reduces i nterference generated by the PCM on
some radi o frequenci es used i n two-way radi o com-
muni cati ons. However, thi s uni t wi l l not resol ve com-
pl ai nts of RFI i n the commerci al AM or FM radi o
frequency ranges.
AUDIO SYSTEM
INJURY
Audio System Diagnosis
NO AUDIO. 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
6. Speakers faulty.
1. Check radio fuses in fuseblock
module. Replace fuses, if required.
2. Check for loose or corroded radio
connector. Repair, if required.
3. Check for battery voltage at radio
connector. Repair wiring, if required.
4. Check for continuity between radio
chassis and a known good ground.
There should be continuity. Repair
ground, if required.
5. Exchange or replace radio, if
required.
6. See speaker diagnosis, in this
group.
NO DISPLAY. 1. Fuse faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
1. Check radio fuses in fuseblock
module. Replace fuses, if required.
required.
CLOCK WILL NOT KEEP SET
TIME.
1. Fuse faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
1. Check ignition-off draw fuse.
Replace fuse, if required.
required.
POOR RADIO RECEPTION. 1. Antenna faulty.
2. Ground faulty.
3. Radio faulty.
1. See antenna diagnosis, in this
group. Repair or replace antenna, if
required.
ground, if required..
required.
NO/POOR TAPE OPERATION. 1. Faulty tape.
2. Foreign objects behind tape door.
3. Dirty cassette tape head.
4. Faulty tape deck.
1. Insert known good tape and test
operation.
2. Remove foreign objects and test
operation.
3. Clean head with Mopar Cassette
Head Cleaner.
required.
NO COMPACT DISC OPERATION 1. Faulty CD.
2. Foreign material on CD.
3. Condensation on CD or optics.
4. Faulty CD player.
1. Insert known good CD and test
operation.
2. Clean CD and test operation.
3. Allow temperature of vehicle interior
to stabilize and test operation.
required.
RADIO
I f the vehi cl e i s equi pped wi th remote radi o
swi tches l ocated on the backs of the steeri ng wheel
spokes, and the probl em bei ng di agnosed i s rel ated to
one of the symptoms l i sted bel ow, be certai n to check
the remote radi o swi tches and ci rcui ts as descri bed
i n thi s group, pri or to attempti ng radi o di agnosi s or
repai r.
Stati ons changi ng wi th no remote radi o swi tch
i nput
Radi o memory presets not worki ng properl y
Vol ume changes wi th no remote radi o swi tch
i nput
Remote radi o swi tch buttons taki ng on other
functi ons
CD pl ayer ski ppi ng tracks
Remote radi o swi tch i noperati ve.
8W-47 - Audi o System i n Group 8W - Wi ri ng Di a-
grams.
INJURY.
CAUTION: The speaker output of the radio is a
floating ground system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
(1) Check the fuse(s) i n the juncti on bl ock and the
Power Di stri buti on Center (PDC). I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse(s).
(2) Check for battery vol tage at the fuse i n the
PDC. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the battery as requi red.
(3) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fuse i n the juncti on
Remove the i nstrument cl uster bezel . Remove the
radi o, but do not unpl ug the wi re harness connectors.
Check for conti nui ty between the radi o chassi s and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 5. I f not OK, repai r the open radi o chassi s
ground ci rcui t as requi red.
(5) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output ci rcui t
cavi ty of the l eft (gray) radi o wi re harness connector.
I f OK, go to Step 6. I f not OK, repai r the open ci rcui t
as requi red.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the l eft (gray) radi o wi re harness connector.
I f OK, repl ace the faul ty radi o. I f not OK, repai r the
open ci rcui t to the I gni ti on-Off Draw (I OD) fuse as
requi red.
REMOTE RADIO SWITCH
INJURY.
cabl e. Wai t two mi nutes for the ai rbag system capac-
i tor to di scharge before further servi ce.
(2) Remove the remote radi o swi tch as descri bed i n
thi s group.
(3) Use an ohmmeter to check the swi tch resi s-
tance as shown i n the Remote Radi o Swi tch Test
chart.
(4) I f the swi tch resi stance checks OK, go to Step
5. I f not OK, repl ace the faul ty swi tch.
(5) Check for conti nui ty between the ground ci r-
cui t cavi ty of the swi tch wi re harness connector and
a good ground. There shoul d be conti nui ty. I f OK, go
to Step 6. I f not OK, repai r the open ci rcui t as
requi red.
(6) Unpl ug the 24-way whi te wi re harness connec-
tor from the Body Control Modul e (BCM). Check for
conti nui ty between the radi o control mux ci rcui t cav-
i ty of the remote radi o swi tch wi re harness connector
and a good ground. There shoul d be no conti nui ty. I f
Remote Radio Switch Test
Switch Position Resistance
Volume Up 7320 Ohms
Volume Down 1210 Ohms
Seek Up 4530 Ohms
Seek Down 2050 Ohms
Pre-Set Station Advance 10 Ohms
OK, go to Step 7. I f not OK, repai r the short ci rcui t
as requi red.
(7) Check for conti nui ty between the radi o control
mux ci rcui t cavi ti es of the remote radi o swi tch wi re
harness connector and the BCM wi re harness connec-
tor. There shoul d be conti nui ty. I f OK, refer to the
proper Body Di agnosti c Procedures manual to test
the BCM and the CCD data bus. I f not OK, repai r
SPEAKER
grams.
INJURY.
CAUTION: The speaker output of the radio is a
floating ground system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
Turn the radi o on. Adjust the bal ance and fader con-
trol s to check the performance of each i ndi vi dual
speaker. Note the speaker l ocati ons that are not per-
formi ng correctl y. Go to Step 2.
(2) Turn the radi o off. Turn the i gni ti on swi tch to
the Off posi ti on. Di sconnect and i sol ate the battery
negati ve cabl e. Remove the i nstrument cl uster bezel
and remove the radi o as descri bed i n thi s group. I f
the vehi cl e i s equi pped wi th the I nfi ni ty Gol d
speaker package, al so unpl ug the wi re harness con-
nectors at the ampl i fi er. Check both the speaker feed
(+) ci rcui t and return (-) ci rcui t cavi ti es for the i nop-
erati ve speaker l ocati on(s) at the radi o wi re harness
connectors for conti nui ty to ground. I n each case,
there shoul d be no conti nui ty. I f OK, go to Step 3. I f
not OK, repai r the shorted speaker ci rcui t(s) as
requi red.
(3) I f the vehi cl e i s equi pped wi th the I nfi ni ty Gol d
speaker package, go to Step 6. I f the vehi cl e i s
equi pped wi th the standard speaker system, check
the resi stance between the speaker feed (+) ci rcui t
and return (-) ci rcui t cavi ti es of the radi o wi re har-
ness connectors for the i noperati ve speaker l oca-
ti on(s). The meter shoul d read between 3 and 8 ohms
(speaker resi stance). I f OK, go to Step 4. I f not OK,
go to Step 5.
(4) I nstal l a known good radi o. Connect the bat-
tery negati ve cabl e. Turn the i gni ti on swi tch to the
On posi ti on. Turn on the radi o and test the speaker
operati on. I f OK, repl ace the faul ty radi o. I f not OK,
turn the radi o off, turn the i gni ti on swi tch to the Off
posi ti on, di sconnect and i sol ate the battery negati ve
cabl e, remove the test radi o, and go to Step 5.
(5) Unpl ug the speaker wi re harness connector at
the i noperati ve speaker. Check for conti nui ty
between the speaker feed (+) ci rcui t cavi ti es of the
radi o wi re harness connector and the speaker wi re
harness connector. Repeat the check between the
speaker return (-) ci rcui t cavi ti es of the radi o wi re
harness connector and the speaker wi re harness con-
nector. I n each case, there shoul d be conti nui ty. I f
OK, repl ace the faul ty speaker. I f not OK, repai r the
open ci rcui t(s) as requi red.
(6) For each i noperati ve speaker l ocati on, check for
conti nui ty between the speaker feed (+) ci rcui t cavi -
ti es of the radi o wi re harness connectors and the
ampl i fi er wi re harness connectors. Repeat the check
for each i noperati ve speaker l ocati on between the
speaker return (-) ci rcui t cavi ti es of the radi o wi re
harness connectors and the ampl i fi er wi re harness
connectors. I n each case, there shoul d be conti nui ty.
as requi red.
(7) Check for conti nui ty between the two ground
ci rcui t cavi ti es of the ampl i fi er wi re harness connec-
tor and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 8. I f not OK, repai r the open ci rcui t(s)
as requi red.
(8) Check the ampl i fi er fuse i n the juncti on bl ock.
I f OK, go to Step 9. I f not OK, repai r the shorted ci r-
cui t or component as requi red and repl ace the faul ty
fuse.
(9) Check for battery vol tage at the ampl i fi er fuse
i n the juncti on bl ock. I f OK, go to Step 10. I f not OK,
repai r the open ci rcui t to the PDC as requi red.
(10) I nstal l the radi o. Connect the battery negati ve
cabl e. Check for battery vol tage at the two fused B(+)
ci rcui t cavi ti es of the ampl i fi er wi re harness connec-
tor. I f OK, go to Step 11. I f not OK, repai r the open
ci rcui t to the fuse i n the juncti on bl ock as requi red.
Turn the radi o on. Check for battery vol tage at the
radi o 12 vol t output ci rcui t cavi ty of the ampl i fi er
wi re harness connector. I f OK, go to Step 12. I f not
OK, repai r the open ci rcui t to the radi o as requi red.
(12) Turn the radi o off. Turn the i gni ti on swi tch to
the Off posi ti on. Di sconnect and i sol ate the battery
negati ve cabl e. For each i noperati ve speaker l ocati on,
check both the ampl i fi ed feed (+) ci rcui t and the
ampl i fi ed return (-) ci rcui t cavi ti es of the ampl i fi er
wi re harness connectors for conti nui ty to ground. I n
each case there shoul d be no conti nui ty. I f OK, go to
Step 13. I f not OK, repai r the short ci rcui t as
requi red.
(13) For each i noperati ve speaker l ocati on, check
the resi stance between the ampl i fi ed feed (+) ci rcui t
and the ampl i fi ed return (-) ci rcui t cavi ti es of the
ampl i fi er wi re harness connectors. The meter shoul d
read between 3 and 8 ohms (speaker resi stance). I f
OK, repl ace the faul ty ampl i fi er. I f not OK, go to
Step 14.
(14) Unpl ug the speaker wi re harness connector at
the i noperati ve speaker. Check for conti nui ty
between the ampl i fi ed feed (+) ci rcui t cavi ti es of the
speaker wi re harness connector and the ampl i fi er
wi re harness connector. Repeat the check between
the ampl i fi ed return (-) ci rcui t cavi ti es of the speaker
wi re harness connector and the ampl i fi er wi re har-
ness connector. I n each case there shoul d be conti nu-
i ty. I f OK, repl ace the faul ty speaker. I f not OK,
ANTENNA
NO OR POOR RADIO RECEPTION
INJURY.
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
Test 1 - Mast to ground test
Test 2 - Ti p-of-mast to ti p-of-conductor test
Test 3 - Body ground to battery ground test
Test 4 - Body ground to coaxi al shi el d test.
The ohmmeter test l ead connecti ons for each test
are shown i n Antenna Tests (Fi g. 1).
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the
coaxial cable connection under the right end of the
instrument panel near the right cowl side panel to
the antenna base, and then from the coaxial cable
connection to the radio chassis connection.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from the base. Proceed as fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s and i sol ate.
(2) Connect one ohmmeter l ead to the ti p of the
antenna mast and the other l ead to the antenna
base. Check for conti nui ty.
(3) There shoul d be no conti nui ty. I f conti nui ty i s
found, repl ace the faul ty or damaged fi xed antenna
base and cabl e assembl y or power antenna uni t.
TEST 2
Test 2 checks the antenna for an open ci rcui t as
fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
center pi n of the antenna coaxi al cabl e connector.
(3) Conti nui ty shoul d exi st (the ohmmeter shoul d
onl y regi ster a fracti on of an ohm). Hi gh or i nfi ni te
resi stance i ndi cates damage to the fi xed antenna
base and cabl e assembl y or the power antenna uni t.
Repl ace the faul ty antenna uni t, i f requi red.
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. Thi s test shoul d be performed
wi th the battery posi ti ve cabl e removed from the bat-
tery. Di sconnect both battery cabl es, the negati ve
cabl e fi rst. Reconnect the battery negati ve cabl e and
perform the test as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the battery
negati ve post.
(2) The resi stance shoul d be l ess than one ohm.
Fig. 1 Antenna Tests
(3) I f the resi stance i s more than one ohm, check
the brai ded ground strap connected to the engi ne and
the vehi cl e body for bei ng l oose, corroded, or dam-
aged. Repai r the ground strap connecti on, i f requi red.
TEST 4
Test 4 checks the condi ti on of the ground between
the antenna base and the vehi cl e body as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the outer cri mp
on the antenna coaxi al cabl e connector.
(2) The resi stance shoul d be l ess then one ohm.
(3) I f the resi stance i s more then one ohm, cl ean
and/or ti ghten the antenna base to fender mounti ng
hardware.
NO OR POOR POWER ANTENNA OPERATION
grams.
INJURY.
to Step 2. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
juncti on bl ock. I f OK, go to Step 3. I f not OK, repai r
the open ci rcui t to the fuse i n the Power Di stri buti on
Center (PDC) as requi red.
(3) Unpl ug the power antenna motor wi re harness
connector from the juncti on bl ock and use two
jumper wi res to check the antenna operati on. Con-
nect one end of one jumper wi re to a known good
ground and attach one end of the other jumper wi re
to a good battery feed. Test the antenna operati on as
fol l ows:
NOTE: The power antenna will not operate in the
down direction when it is fully-retracted, or in the
up direction when it is fully-extended. Limit
switches within the power antenna unit are
designed to prevent the motor from operating
beyond the antenna up and down limits.
(a) To test the antenna Up operati on, connect
the ground jumper to the power antenna up control
ci rcui t cavi ty of the power antenna motor wi re har-
ness connector; and, connect the battery feed
jumper to the power antenna dri ver ci rcui t cavi ty
of the power antenna motor wi re harness connec-
tor.
(b) To test the antenna Down operati on, connect
the ground jumper to the power antenna dri ver ci r-
cui t cavi ty of the power antenna motor wi re har-
ness connector; and, connect the battery feed
jumper to the power antenna down control ci rcui t
cavi ty of the power antenna motor wi re harness
connector.
(4) I f the antenna mast fai l s to operate i n one or
both di recti ons, repl ace the faul ty power antenna
uni t. I f the antenna mast operates i n both di recti ons,
test the antenna rel ay as descri bed i n thi s group.
ANTENNA RELAY
grams.
INJURY.
(1) Remove the antenna rel ay from the juncti on
bl ock as descri bed i n thi s group. Go to Step 2.
(2) Check for conti nui ty between the rel ay ground
ci rcui t cavi ty i n the juncti on bl ock and a known good
ground. There shoul d be conti nui ty. I f OK, go to Step
3. I f not OK, repai r the open ci rcui t as requi red.
(3) Check for battery vol tage at the rel ay fused
B(+) ci rcui t cavi ty i n the juncti on bl ock. I f OK, go to
Step 4. I f not OK, repai r the open ci rcui t to the fuse
i n the juncti on bl ock as requi red.
Check for battery vol tage at the rel ay radi o 12 vol t
output ci rcui t cavi ty i n the juncti on bl ock. There
shoul d be vol tage wi th the radi o turned on, and no
vol tage wi th the radi o turned off. I f OK, repl ace the
faul ty rel ay. I f not OK, repai r the open ci rcui t to the
radi o as requi red.
RADIO FREQUENCY INTERFERENCE
INJURY.
I nspect the ground connecti ons at the fol l owi ng:
Bl ower motor
El ectri c fuel pump
Generator
I gni ti on modul e
Wi per motor
Antenna coaxi al ground
Radi o ground
Body-to-engi ne brai ded ground strap (i f the vehi -
cl e i s so equi pped).
Cl ean, ti ghten, or repai r the connecti ons as
requi red.
Al so i nspect the fol l owi ng secondary i gni ti on sys-
tem components, as descri bed i n Group 8D - I gni ti on
Systems:
Spark pl ug wi re routi ng and condi ti on
Di stri butor cap and rotor
I gni ti on coi l
Spark pl ugs.
Reroute the spark pl ug wi res or repl ace the faul ty
components as requi red.
SERVICE PROCEDURES
ANTITHEFT SECURITY CODE
Certai n export model s equi pped wi th the RBL
sal es code radi o have a radi o anti theft securi ty code
feature. Thi s feature requi res that a securi ty code be
entered i nto the radi o fol l owi ng a battery di sconnect
i n order for the radi o to become operati onal . When
the radi o i s new, a l abel i denti fyi ng the four-di gi t
securi ty code i s affi xed to the radi o facepl ate. I t i s
recommended that the vehi cl e owner note thi s secu-
ri ty code i n hi s vehi cl e owners manual for future ref-
erence, then remove and destroy the securi ty code
l abel . To enter the securi ty code i n the radi o, proceed
as fol l ows:
(2) Momentari l y depress the power (PWR) button
on the radi o facepl ate. The word code shoul d
appear on the radi o di spl ay.
(3) Enter the four-di gi t radi o securi ty code by
depressi ng the radi o stati on preset buttons i n the
proper sequence.
(4) The radi o i s now ready for normal operati on.
The securi ty code must be reentered any ti me the
radi o or vehi cl e i s di sconnected from battery feed.
I f an attempt i s made to enter an i ncorrect securi ty
code i nto the radi o, the radi o wi l l become i noperati ve
and the words wai t 2 hrs wi l l appear on the radi o
di spl ay. The i gni ti on swi tch and the radi o power but-
ton must remai n i n thei r On posi ti ons for two ful l
and uni nterrupted hours, before the word code wi l l
reappear i n the radi o di spl ay and the radi o wi l l
agai n accept a securi ty code entry.
RADIO
INJURY.
cabl e.
(2) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , pry gentl y around the edges of the
i nstrument panel swi tch pod bezel s and remove both
bezel s.
(3) Remove the ten screws that secure the cl uster
(4) Pul l the cl uster bezel rearward and move i t
outboard of the steeri ng wheel to remove i t from the
vehi cl e.
(5) Remove the two screws from the front of the
radi o that secure i t to the i nstrument panel (Fi g. 3).
(6) Pul l the radi o out from the i nstrument panel
far enough to unpl ug the wi re harness connectors
and the antenna coaxi al cabl e connector (Fi g. 4).
CLUSTER BEZEL SCREWS
that secures the ground wi re to the radi o chassi s and
remove the radi o from the vehi cl e.
Ti ghten the radi o mounti ng screws to 5 Nm (45 i n.
l bs.).
REMOTE RADIO SWITCH
INJURY.
cabl e.
(2) Remove the three screws that secure the dri ver
ai rbag modul e to the steeri ng wheel (Fi g. 5).
(3) Pul l the ai rbag modul e away from the steeri ng
wheel far enough to unpl ug the ai rbag and horn
swi tch wi re harness connectors from the back of the
ai rbag modul e.
(4) Remove the ai rbag modul e from the steeri ng
wheel .
(5) Remove the screws that secure the speed con-
trol swi tches to the steeri ng wheel , and l ower the
swi tches from the steeri ng wheel spokes (Fi g. 6).
(6) Remove the two screws that secure the remote
radi o swi tch to the steeri ng wheel spoke (Fi g. 7).
(7) Unpl ug the wi re harness connector from the
remote radi o swi tch.
(8) Remove the remote radi o swi tch from the steer-
i ng wheel .
Ti ghten the screws that secure the ai rbag modul e to
the steeri ng wheel to 10.2 Nm (90 i n. l bs.).
AMPLIFIER
cabl e.
Fig. 3 Radio Remove/Install
RADIO MOUNTING SCREWS
Fig. 4 Radio Connectors
GRAY 7WAY CONNECTOR
CCD DATA BUS CONNEC- TOR
Fig. 5 Driver Airbag Module Remove/Install
DRIVERS AIRBAG MODULE AIRBAG WIRE HORN SWITCH WIRE SCREWS FWD
Fig. 6 Speed Control Switches Remove/Install
SPEED CONTROL SWITCHES
MOUNTING SCREWS
(2) Di sengage the l eft rear seat cushi on l atch by
pul l i ng upward on the rel ease strap. Ti l t the seat
cushi on forward.
(3) Li ft the carpeti ng i n the under-seat area as
requi red to access the ampl i fi er.
(4) Unpl ug the two wi re harness connectors from
the ampl i fi er (Fi g. 8).
(5) Remove the three screws that secure the ampl i -
fi er to the fl oor.
(6) Remove the ampl i fi er.
Ti ghten the ampl i fi er mounti ng screws to 2.8 Nm
(25 i n. l bs.).
SPEAKER
INSTRUMENT PANEL
INJURY.
cabl e.
(3) I f the vehi cl e i s so equi pped, pul l the panel up
far enough to unpl ug the wi re harness connector for
the sol ar sensor, or to remove the sol ar sensor from
the cowl top tri m.
cl e.
(5) Unpl ug the speaker wi re harness connector.
(6) Remove the two screws that secure the speaker
to the i nstrument panel (Fi g. 10).
Fig. 7 Remote Radio Switches Remove/Install
REMOTE RADIO SWITCHES
MOUNTING SCREWS
Fig. 8 Amplifier Remove/Install - Typical
CONNECTORS
RADIO AMPLIFIER
RETAINING SCREWS
Fig. 10 Instrument Panel Speaker Remove/Install
MOUNTING SCREWS
(7) Remove the speaker from the i nstrument
panel .
FRONT DOOR
cabl e.
(2) Remove the bezel near the i nsi de door l atch
rel ease handl e by i nserti ng a strai ght-bl aded screw-
dri ver i n the notched end and pryi ng gentl y upwards.
(3) Remove the screw l ocated i n the bezel openi ng
near the i nsi de door l atch rel ease handl e that secures
the tri m panel to the i nner door panel (Fi g. 11).
(4) Remove the tri m cap and screw near the rear
of the door armrest.
(5) Remove the tri m cap and screw at the upper
front corner of the tri m panel .
(6) Remove the screw l ocated above the front door
speaker gri l l e.
sti ck, gentl y pry the tri m panel away from the door
around the peri meter to rel ease the tri m panel
retai ners.
NOTE: To aid in the removal of the trim panel, start
at the bottom of the panel.
(8) Pul l the tri m panel away from the i nner door
panel far enough to unpl ug the wi re harness connec-
tors from the door modul e and, i f the vehi cl e i s so
equi pped, from the door courtesy l amp.
speaker to the l ower front corner of the i nner door
panel (Fi g. 12).
(10) Pul l the speaker away from the i nner door
panel far enough to unpl ug the speaker wi re harness
connector.
(11) Remove the speaker from the door.
Ti ghten the hardware as fol l ows:
Speaker mounti ng screws - 1.1 Nm (10 i n. l bs.)
Tri m panel mounti ng screws - 1.3 Nm (12 i n.
l bs.).
REAR DOOR
cabl e.
(3) Remove the screw l ocated i n the bezel openi ng
near the i nsi de door l atch rel ease handl e that secures
the tri m panel to the i nner door panel (Fi g. 13).
Fig. 11 Front Door Trim Panel Remove/Install
U-NUT
FRONT DOOR
U-NUT
Fig. 12 Front Door Speaker Remove/Install
KEY CYLINDER SWITCH CONNECTOR POWER LOCK/WINDOW SWITCH CONNECTOR POWER MIRROR SWITCH CON- NECTOR POWER MIR- ROR CONNEC- TOR PLASTIC NUT SPEAKER SCREW POWER WIN- DOW MOTOR COURTESY LAMP CONNECTOR POWER LOCK MOTOR
Fig. 13 Rear Door Trim Panel Remove/Install
REAR DOOR U-NUT TRIM PANEL PLUG BEZEL FWD
sti ck, gentl y pry the tri m panel away from the door
around the peri meter to rel ease the tri m panel
retai ners.
(6) Pul l the tri m panel away from the i nner door
panel far enough to unpl ug the wi re harness connec-
tor from the power wi ndow swi tch.
speaker to the l ower front corner of the i nner door
panel (Fi g. 14).
(8) Pul l the speaker away from the i nner door
panel far enough to unpl ug the speaker wi re harness
connector.
(9) Remove the speaker from the door.
Speaker mounti ng screws - 1.1 Nm (10 i n. l bs.)
Tri m panel mounti ng screws - 1.3 Nm (12 i n.
l bs.).
SOUND BAR
TWEETER
(1) Remove the sound bar from the vehi cl e as
tweeter.
(3) From the i nsi de of the sound bar, use a pai r of
si de cutters to cut and remove the push-nut type
retai ner that secures the tweeter to the sound bar
(Fi g. 15).
(4) Push the tweeter out of the mounti ng hol e from
the i nsi de of the sound bar.
Al ways use a new push-nut retai ner on the tweeter.
WOOFER
(1) Remove the sound bar from the vehi cl e as
woofer.
(3) From the i nsi de of the sound bar, strai ghten
the tabs that secure the speaker gri l l e to the sound
bar (Fi g. 15).
(4) From the outsi de of the sound bar, remove the
speaker gri l l e.
(5) Careful l y dri l l out the four ri vets that secure
the woofer to the sound bar.
(6) Remove the woofer from the sound bar.
(7) Reverse the removal procedures to i nstal l . Use
new ri vets i nstal l ed from the i nsi de of the sound bar
to secure the woofer.
SOUND BAR
cabl e.
(2) Gentl y pry at the edge of the fi ve snap-fi t
screw covers on the sound bar to remove them (Fi g.
16).
Fig. 14 Rear Door Speaker Remove/Install
POWER WINDOW MOTOR POWER WINDOW SWITCH CONNECTOR POWER LOCKMOTOR PLASTICNUT SCREW SPEAKER FWD
POWER WINDOW MOTOR CONNECTOR
Fig. 15 Sound Bar Speakers Remove/Install
RETAINER
TWEETER
WOOFER
(3) Remove the fi ve screws that secure the sound
bar to the upper l i ftgate openi ng rei nforcement.
(4) Lower the sound bar far enough to unpl ug the
wi re harness connector near the ri ght end of the
sound bar.
(5) Remove the sound bar from the vehi cl e.
When i nstal l i ng the sound bar, be certai n to rei nstal l
a spacer on each screw between the sound bar and
the upper l i ftgate openi ng rei nforcement.
ANTENNA
INJURY.
FIXED ANTENNA
cabl e.
(2) Remove the ri ght front i nner fender l i ner. Refer
to Group 23 - Body for the procedures.
(3) Unscrew the antenna mast from the antenna
body (Fi g. 17).
(4) Remove the antenna cap nut and adapter usi ng
an antenna nut wrench (Speci al Tool C-4816) (Fi g.
18).
(5) Lower the antenna body and cabl e assembl y
through the fender far enough to access the antenna
body through the ri ght front fender wheel housi ng
(Fi g. 19).
(6) Remove the fuse access panel i n the ri ght cowl
si de tri m panel , and remove the push nut that
secures the tri m panel to the juncti on bl ock (Fi g. 20).
cowl si de tri m panel to the front door openi ng tri m
and remove the cowl si de ki ck panel tri m.
(8) Locate the antenna coaxi al cabl e connector
near the juncti on bl ock at the ri ght cowl si de panel .
Unpl ug the connector by pul l i ng i t apart whi l e twi st-
i ng the metal connector hal ves (Fi g. 21). Do not pul l
on the cabl e.
(9) Di sengage the coaxi al cabl e grommet from the
hol e i n the ri ght cowl si de outer panel . Access the
grommet from i nsi de the ri ght front fender wheel
housi ng.
(10) Pul l the coaxi al cabl e out through the ri ght
cowl si de outer panel and remove the antenna body
and cabl e from the vehi cl e.
Ti ghten the antenna cap nut to 7.9 Nm (70 i n. l bs.).
Ti ghten the antenna mast to 3.3 Nm (30 i n. l bs.).
POWER ANTENNA
cabl e.
Fig. 16 Sound Bar Remove/Install
TWEETER
SOUND BAR
SCREW
Fig. 17 Fixed Antenna Mast Remove/Install- Typical
ANTENNA MAST
CAP NUT
ADAPTER
Fig. 18 Fixed Antenna Cap Nut and Adapter
Remove/Install - Typical
CAP NUT ANTENNA ADAPTER TOOL
(2) Remove the ri ght front i nner fender l i ner. Refer
to Group 23 - Body for the procedures.
(3) Remove the antenna cap nut and escutcheon
usi ng an antenna nut wrench (Speci al Tool C-4816)
(Fi g. 22).
(4) Remove the fuse access panel i n the ri ght cowl
si de tri m panel , and remove the push nut that
secures the tri m panel to the juncti on bl ock (Fi g. 20).
cowl si de tri m panel to the front door openi ng tri m
and remove the cowl si de ki ck panel tri m.
(6) Locate the antenna coaxi al cabl e connector
near the juncti on bl ock at the ri ght cowl si de panel .
Unpl ug the connector by pul l i ng i t apart whi l e twi st-
i ng the metal connector hal ves (Fi g. 21). Do not pul l
on the cabl e.
(7) Unpl ug the power antenna wi re harness con-
nector from the juncti on bl ock.
(8) Remove the antenna mounti ng bol ts (Fi g. 22).
(9) Di sengage the coaxi al cabl e grommet from the
hol e i n the ri ght cowl si de outer panel . Access the
grommet from i nsi de the ri ght front fender wheel
housi ng.
Fig. 19 Fixed Antenna Body and Cable Remove/
Install
MAST
CAPNUT
ANTENNA LEAD
Fig. 21 Antenna Coaxial Cable Connector -Typical
ANTENNA LEAD
Fig. 22 Power Antenna Remove/Install
CAPNUT ESCUTCHEON POWER ANTENNA BOLT (2) ANTENNA LEAD
(10) Pul l the antenna wi re harness and coaxi al
cabl e out through the ri ght cowl si de outer panel and
remove the power antenna uni t from the vehi cl e.
Antenna cap nut - 7.9 Nm (70 i n. l bs.)
Antenna mounti ng bol ts - 8.4 Nm (75 i n. l bs.).
ANTENNA RELAY
INJURY.
cabl e.
(3) Remove the push-nut that secures the ri ght
23).
tri m.
(6) Unpl ug the antenna rel ay from the juncti on
bl ock.
(7) I nstal l the antenna rel ay by al i gni ng the rel ay
termi nal s wi th the cavi ti es i n the juncti on bl ock and
pushi ng the rel ay fi rml y i nto pl ace.
(9) Test the antenna rel ay operati on.
(10) I nstal l the ri ght cowl si de tri m panel and the
fuse access panel .
HORN SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
components i n the factory-i nstal l ed horn systems.
Refer to 8W-41 - Horns/Ci gar Li ghter i n Group 8W -
Wi ri ng Di agrams for compl ete ci rcui t descri pti ons
and di agrams.
HORN RELAY
The horn rel ay i s a I nternati onal Standards Orga-
ni zati on (I SO) mi cro-rel ay. The termi nal desi gnati ons
and functi ons are the same as a conventi onal I SO
rel ay. However, the mi cro-rel ay termi nal ori entati on
(or footpri nt) i s di fferent, current 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 horn rel ay i s a el ectromechani cal devi ce that
swi tches battery current to the horn when the horn
swi tch grounds the rel ay coi l . 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 horn rel ay.
The horn rel ay i s l ocated i n the Power Di stri buti on
Center (PDC), i n the engi ne compartment. Refer to
the PDC l abel for rel ay i denti fi cati on and l ocati on.
I f a probl em i s encountered wi th a conti nuousl y
soundi ng horn, i t can usual l y be qui ckl y resol ved by
removi ng the horn rel ay from the PDC unti l further
di agnosi s i s compl eted.
The horn rel ay cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
HORN SWITCH
A center-bl ow, resi sti ve membrane type horn
swi tch i s i nstal l ed on the back si de of the dri ver si de
ai rbag modul e tri m cover i n the center of the steer-
i ng wheel . When the center area of the ai rbag tri m
cover i s depressed, the horn swi tch compl etes a ci r-
cui t to ground for the coi l si de of the horn rel ay. The
steeri ng wheel and steeri ng col umn must be properl y
grounded for the horn swi tch to functi on.
The horn swi tch i s onl y servi ced as a part of the
ai rbag modul e tri m cover. I f the horn swi tch shoul d
fai l , or i f the ai rbag i s depl oyed, the ai rbag modul e
tri m cover and horn swi tch uni t must be repl aced.
HORN
The standard, dual -note, el ectromagneti c di a-
phragm-type horns are secured next to each other on
a bracket beneath the ri ght radi ator cl osure exten-
si on panel and forward of the ri ght front i nner
wheel house. The two horns are connected i n paral l el
and are grounded through thei r wi re harness connec-
tor and ci rcui t to an eyel et bol ted to the ri ght i nner
fender shi el d near the Power Di stri buti on Center
(PDC), and recei ve battery feed through the cl osed
contacts of the horn rel ay.
The horns cannot be repai red or adjusted and, i f
faul ty or damaged, they must be repl aced.
ZG HORN SYSTEMS 8G - 1
BODY CONTROL MODULE
The horn system i s one of the outputs of the BCM.
The BCM i s programmed to energi ze or de-energi ze
the horn rel ay i n response to certai n i nputs from the
Vehi cl e Theft Securi ty System (VTSS) and the
Remote Keyl ess Entry (RKE) system. Refer to Group
8P - Power Lock Systems for more i nformati on on the
RKE system. Refer to Group 8Q - Vehi cl e Theft/Secu-
ri ty Systems for more i nformati on on the VTSS.
HORN RELAY
8W-41 - Horns/Ci gar Li ghter i n Group 8W - Wi ri ng
Di agrams.
INJURY.
RELAY TEST
Center (PDC) i n the engi ne compartment. Refer to
the PDC l abel for horn rel ay i denti fi cati on and l oca-
ti on.
Remove the horn rel ay from the PDC as descri bed
i n thi s group to perform the fol l owi ng tests:
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
to the horn(s). There shoul d be conti nui ty between
the cavi ty for rel ay termi nal 87 and the horn rel ay
output ci rcui t cavi ty of each horn wi re harness con-
nector 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 horn(s) as requi red.
the el ectromagnet i n the rel ay. I t i s connected to bat-
tery vol tage and shoul d be hot at al l ti mes. Check for
battery vol tage at the cavi ty for rel ay termi nal 86. 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.
Horn Relay
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
8G - 2 HORN SYSTEMS ZG
the el ectromagnet i n the rel ay. I t i s grounded
through the horn swi tch when the horn swi tch i s
depressed. I t can al so be grounded by the Body Con-
trol Modul e (BCM) i n response to i nputs from the
Vehi cl e Theft Securi ty System (VTSS) or the Remote
Keyl ess Entry (RKE) system. Check for conti nui ty to
ground at the cavi ty for rel ay termi nal 85. There
shoul d be conti nui ty wi th the horn swi tch depressed,
and no conti nui ty wi th the horn swi tch rel eased. I f
not OK, see the di agnosi s for the Horn Swi tch i n thi s
group.
HORN SWITCH
Di agrams.
INJURY.
cabl e. Remove the l ower steeri ng col umn cover/knee
bl ocker. Check for conti nui ty between the metal
steeri ng col umn jacket and a good ground. There
refer to Group 19 - Steeri ng and check for proper
i nstal l ati on of the steeri ng col umn ground cl i p.
(2) Remove the dri ver si de ai rbag modul e as
descri bed i n Group 8M - Passi ve Restrai nt Systems.
Unpl ug the horn swi tch wi re harness connectors
from the ai rbag modul e. Unpl ug the Body Control
Modul e (BCM) wi re harness connector B (whi te).
Unpl ug the horn rel ay from the Power Di stri buti on
Center (PDC). Check for conti nui ty between the
steeri ng col umn hal f of the horn swi tch feed wi re
harness connector and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 3. I f not OK,
repai r the short ci rcui t as requi red.
(3) Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and the horn rel ay control ci rcui t cavi ty for
the horn rel ay i n the PDC. There shoul d be conti nu-
i ty. I f OK, go to Step 4. I f not OK, repai r the open
ci rcui t as requi red.
(4) Check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
ai rbag modul e. There shoul d be no conti nui ty. I f OK,
go to Step 5. I f not OK, repl ace the faul ty horn
swi tch.
(5) Depress the center of the ai rbag modul e cover
and check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
ai rbag modul e. There shoul d now be conti nui ty. I f not
OK, repl ace the faul ty horn swi tch.
HORN
Di agrams.
(1) Unpl ug the horn wi re harness connector. Mea-
sure the resi stance between the ground ci rcui t cavi ty
of the horn wi re harness connector and a good
ground. There shoul d be no measurabl e resi stance. I f
OK, go to Step 2. I f not OK, repai r the ci rcui t to
(2) Wi th the horn wi re harness connector sti l l
unpl ugged, depress the horn swi tch. There shoul d be
battery vol tage at the horn rel ay output ci rcui t cavi ty
of the horn wi re harness connector. I f OK, repl ace
the faul ty horn. I f not OK, repai r the open ci rcui t to
the horn rel ay as requi red.
HORN RELAY
cabl e.
(3) Refer to the l abel on the PDC for horn rel ay
(4) Unpl ug the horn rel ay from the PDC.
(5) I nstal l the horn rel ay by al i gni ng the rel ay ter-
mi 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.
NEGATIVE CABLE
ZG HORN SYSTEMS 8G - 3
HORN SWITCH
WARNING: ON VEHICLES EQUIPPED WITH A
DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTE-
GRAL TO THE AIRBAG MODULE TRIM COVER.
SERVICE OF THIS COMPONENT SHOULD BE PER-
FORMED ONLY BY CHRYSLER-TRAINED AND
AUTHORIZED DEALER SERVICE TECHNICIANS.
FAILURE TO TAKE THE PROPER PRECAUTIONS
OR TO FOLLOW THE PROPER PROCEDURES
COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY. REFER TO GROUP 8M - PAS-
SIVE RESTRAINT SYSTEMS FOR THE SERVICE
PROCEDURES.
HORN
cabl e.
(3) Remove the radi ator l ower ai r defl ector. Refer
to Group 7 - Cool i ng System for the procedures.
(4) Unpl ug the horn wi re harness connectors (Fi g.
2).
(5) Remove the screw that secures the horn
mounti ng bracket to the radi ator cl osure extensi on
panel .
(6) Remove the horns and mounti ng bracket from
the vehi cl e.
Ti ghten the horn mounti ng bracket screw to 30 Nm
(22 ft. l bs.).
Fig. 2 Horn Remove/Install
8G - 4 HORN SYSTEMS ZG
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPEED CONTROL SERVO . . . . . . . . . . . . . . . . 1
SPEED CONTROL SWITCHES . . . . . . . . . . . . . 1
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 1
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 2
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 2
ON-BOARD DIAGNOSTICS TEST FOR SPEED
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 2
OVERSHOOT/UNDERSHOOT ON SPEED
CONTROL SET . . . . . . . . . . . . . . . . . . . . . . . . 6
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPEED CONTROL ELECTRICAL TEST . . . . . . . 5
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 5
VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . 5
POWERTRAIN CONTROL MODULE . . . . . . . . . . 8
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 7
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 7
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
INTRODUCTION
The vehi cl e speed control system i s el ectroni cal l y
control l ed and vacuum operated. The system i s
desi gned to operate between approxi matel y 35 and
85 mph (56 and 137 km/h). Fol l owi ng are general
descri pti ons of the major components i n the speed
control system. For di agnosi s of the enti re speed con-
trol system, refer to the appropri ate Powertrai n
Di agnosti c Procedures servi ce manual and the DRB
scan tool . Refer to Group 8W, Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and wi ri ng di agrams.
SPEED CONTROL SERVO
The speed control servo i s l ocated i n the engi ne
compartment, mounted to a bracket on the ri ght
i nner fender. The servo uni t consi sts of a sol enoi d
val ve body, a vacuum servo and the mounti ng
bracket. The PCM control s the sol enoi d val ve body.
The sol enoi d val ve body control s the appl i cati on and
rel ease of vacuum to the di aphragm of the vacuum
servo. The servo uni t cannot be repai red and i s ser-
vi ced onl y as a compl ete assembl y.
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
the owners manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures. The
i ndi vi dual swi tches cannot be repai red. I f one i ndi -
vi dual swi tch fai l s, the swi tch modul e must be
repl aced.
STOP LAMP SWITCH
Vehi cl es equi pped wi th the speed control opti on use
a dual functi on stop l amp swi tch. The swi tch i s
mounted i n the same l ocati on as the conventi onal
stop l amp swi tch, on the brake pedal mounti ng
bracket under the i nstrument panel . The PCM mon-
i tors the state of the dual functi on stop l amp swi tch.
Refer to Group 5, Brakes for more i nformati on on
stop l amp swi tch servi ce and adjustment procedures.
ZG VEHICLE SPEED CONTROL SYSTEM 8H - 1
SERVO CABLE
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage. Thi s cabl e causes the
throttl e control l i nkage to open or cl ose the throttl e
val ve i n response to movement of the vacuum servo
di aphragm.
The speed control el ectroni c control ci rcui try i s
i ntegrated i nto the Powertrai n Control Modul e
(PCM). The PCM i s l ocated i n the engi ne compart-
ment behi nd the cool ant recovery tank. The PCM
speed control functi ons are moni tored by the
On-Board Di agnosti cs (OBD). Al l OBD-sensed sys-
tems are moni tored by the PCM. Each moni tored ci r-
cui t i s assi gned a Di agnosti c Troubl e Code (DTC).
The PCM wi l l store a DTC i n el ectroni c memory for
certai n fai l ures i t detects. See On-Board Di agnosti c
Test For Speed Control System i n thi s group for more
i nformati on. The PCM cannot be repai red and must
be repl aced i f faul ty.
VACUUM RESERVOIR
The vacuum reservoi r i s mounted bel ow the bat-
tery tray. The reservoi r contai ns a one-way check
val ve to trap engi ne vacuum i n the reservoi r. When
engi ne vacuum drops, as i n cl i mbi ng a grade whi l e
dri vi ng, the reservoi r suppl i es the vacuum needed to
mai ntai n proper speed control operati on. The vacuum
reservoi r cannot be repai red and must be repl aced i f
faul ty.
VEHICLE SPEED SENSOR
The Vehi cl e Speed Sensor (VSS) i s a pul se genera-
tor mounted to an adapter near the transmi ssi on out-
put shaft. The sensor i s dri ven through the adapter
by a speedometer pi ni on gear. The VSS pul se si gnal
i s moni tored by the PCM speed control ci rcui try to
determi ne vehi cl e speed and to mai ntai n speed con-
trol set speed. Refer to the appropri ate Powertrai n
Di agnosti c Procedures manual for di agnosi s and test-
i ng of thi s component. Refer to Group 14, Fuel Sys-
tem for removal /i nstal l ati on procedures.
ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d
be corrected before proceedi ng. Refer to Group 8E,
I nstrument Panel and Gauges for speedometer di ag-
nosi s.
I f a road test veri fi es a system probl em and the
speedometer operates properl y, check for:
A Di agnosti c Troubl e Code (DTC). I f a fl ash
l amp code 15, 34 or 77 exi sts at the Check Engi ne
Lamp (MI L), conduct tests per the Powertrai n Di ag-
nosti c Procedures servi ce manual .
A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
Loose or corroded el ectri cal connecti ons at the
servo. Corrosi on shoul d be removed from el ectri cal
termi nal s and a l i ght coati ng of Mopar Mul ti Purpose
Grease, or equi val ent, appl i ed.
Loose or l eaki ng vacuum hoses or connecti ons.
Secure attachment of both ends of the speed con-
trol servo cabl e.
Smooth operati on of throttl e l i nkage and throttl e
body ai r val ve.
Fai l ed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
ON-BOARD DIAGNOSTICS TEST FOR SPEED
CONTROL SYSTEM
GENERAL INFORMATION
cri ti cal i nput and output ci rcui ts of the speed control
system, maki ng sure they are operati onal . A Di agnos-
ti c Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some ci rcui ts are checked conti nu-
ousl y and some are checked onl y under certai n con-
di ti ons.
I f the OBD system senses that a moni tored ci rcui t
i s bad, i t wi l l put a DTC i nto el ectroni c memory. The
DTC wi l l stay i n el ectroni c memory as l ong as the
ci rcui t conti nues to be bad. The PCM i s programmed
to cl ear the DTCs from memory after 40 engi ne war-
mup cycl es i f the probl em does not occur agai n. The
DRB scan tool may al so be used to erase a DTC.
Diagnostic trouble codes are the results of a
system or circuit failure, but do not directly
identify the failed component or components.
DIAGNOSTIC TROUBLE CODES
The techni ci an can di spl ay a DTC i n three di ffer-
ent ways:
8H - 2 VEHICLE SPEED CONTROL SYSTEM ZG
a two-di gi t number fl ashed on the Mal functi on
I ndi cator (Check Engi ne) Lamp
a two-di gi t number di spl ayed on the vehi cl e
odometer
a descri pti on of the DTC can be read usi ng the
DRB scan tool
Refer to the fol l owi ng Speed Control System Di ag-
nosti c Troubl e Code chart for DTCs whi ch appl y to
the speed control system. Refer to the Powertrai n
Di agnosti c Procedures manual and DRB scan tool to
di agnose an on-board di agnosti c system troubl e code.
OBTAINING DIAGNOSTIC TROUBLE CODES
USING DRB SCAN TOOL
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
ON AN OPERATING ENGINE.
(1) Connect the DRB scan tool to the 16way data
l i nk (di agnosti c) connector. Thi s connector i s l ocated
i n the passenger compartment, bel ow and to the l eft
of steeri ng col umn.
(2) Turn the i gni ti on swi tch on, access Read Faul t
Screen. Record al l the DTCs shown on the DRB scan
tool . Observe the mal functi on i ndi cator (check
engi ne) l amp on the i nstrument panel . The l amp
shoul d l i ght for 2 seconds then go out (bul b check).
(3) To erase DTCs, use the Erase Troubl e Code
data screen on the DRB scan tool .
USING THE MALFUNCTION INDICATOR LAMP (MIL)
(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:
(3) Lamp fl ashes 1 ti me, pauses, and then fl ashes
5 more ti mes. Thi s i ndi cates a DTC code number 15.
(4) 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.
USING THE VEHICLE ODOMETER
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.
SPEED CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
MIL
CODE
GENERIC
SCAN
TOOL
CODE
HEX
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.
15** P0500 23 No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected
during road load conditions.
or
P0720 A6 Low Output Spd Sensr RPM,
Above 15 MPH
Output shaft speed is less than 60 rpm with
vehicle speed above 15 MPH
34** 0F Speed Control Solenoid Circuits An open or shorted condition detected in the
speed control vacuum or vent solenoid
circuits
or
57 Speed Control Switch Always
Low
Speed control switch input below the
minimum
acceptable voltage.
or
56 Speed Control Switch Always
High
Speed control switch input above the
maximum
acceptable voltage.
55* Completion of fault code display on Check
Engine lamp.
77** 52 S/C Power Ckt No power at speed control circuit
* Check Engi ne Lamp (MI L) wi l l not i l l umi nate duri ng engi ne operati on 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 be i l l umi nated duri ng engi ne operati on i f thi s Di agnosti c Troubl e Code
was recorded.
SPEED CONTROL ELECTRICAL TEST
Two di fferent test methods may be used to check
the el ectroni c speed control system. One i nvol ves
usi ng the DRB scan tool . I f thi s test method i s
desi red, refer to the appropri ate Powertrai n Di agnos-
ti c Procedures servi ce manual .
The other test method wi l l i nvol ve the use of a
vol t/ohm meter. The vol t/ohm meter method i s
descri bed wi thi n the tests on the fol l owi ng pages.
Refer to Group 8W, Wi ri ng Di agrams for speed con-
trol el ectri cal schemati cs and connector l ocati on.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
When el ectri cal connecti ons are removed, corrosi on
shoul d be removed from el ectri cal termi nal s and a
l i ght coati ng of Mopar Mul ti -Purpose Grease, or
equi val ent, shoul d be appl i ed.
I nspect connectors for damaged termi nal s. A poor
el ectri cal connecti on can cause a compl ete or i nter-
mi ttent mal functi on. For thi s reason, a poor connec-
ti on may be mi sdi agnosed as a component
mal functi on.
For di agnosi s and testi ng of the Vehi cl e Speed Sen-
sor (VSS), refer to the appropri ate Powertrai n Di ag-
nosti c Procedures servi ce manual . Al so refer to the
DRB scan tool .
For compl ete speed control system di agnosi s, refer
to the appropri ate Powertrai n Di agnosti c Procedures
manual . To test each of the speed control swi tches
onl y, refer to the fol l owi ng:
WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR
RELATED STEERING WHEEL AND STEERING COL-
UMN COMPONENTS, YOU MUST FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM
CAPACITOR TO DISCHARGE BEFORE FURTHER
SYSTEM SERVICE. FAILURE TO DO SO COULD
(1) Di sconnect negati ve battery cabl e. Wai t 2 mi n-
utes for ai rbag system capaci tor to di scharge.
(2) Remove the two speed control swi tch modul es
from steeri ng wheel . Refer to the removal /i nstal l ati on
secti on for procedures.
(3) Check conti nui ty of each i ndi vi dual speed con-
trol swi tch modul e as shown i n chart (Fi g. 1). I f OK,
rei nstal l swi tch. I f not OK, repl ace swi tch modul e
assembl y.
STOP LAMP SWITCH
For conti nui ty checks and swi tch adjustment, refer
to Group 5, Brakes.
VACUUM SUPPLY TEST
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at reservoi r. Di sconnect vacuum l i ne at res-
ervoi r and connect a hand-operated vacuum pump to
reservoi r fi tti ng. Reservoi r vacuum shoul d not bl eed
off. I f vacuum i s bei ng l ost, repl ace reservoi r.
SPEED CONTROL SERVO
For compl ete speed control system di agnosi s, refer
to the appropri ate Powertrai n Di agnosti c Procedures
manual . To test the speed control servo onl y, refer to
the fol l owi ng:
Fig. 1 Speed Control Switch Continuity
SWITCH
The engi ne must be started and runni ng for the
fol l owi ng vol tage tests.
(1) Start engi ne.
(2) Di sconnect 4way el ectri cal connector at servo
(Fi g. 2).
(3) Turn speed control swi tch to ON posi ti on.
(4) Check for battery vol tage at pi n3 of wi ri ng
harness 4way connector (Fi g. 3). Thi s i s the 12 vol t
feed from the stopl amp swi tch. When the brake pedal
i s depressed, vol tage shoul d not be present at pi n3.
I f vol tage i s not present wi th brake pedal not
depressed, check for conti nui ty between servo and
stop l amp swi tch. Al so check stop l amp swi tch
adjustment. Refer to Group 5, Brakes for procedures.
(5) Connect a smal l gauge jumper wi re between
the di sconnected servo harness 4way connector
pi n3, and pi n3 on the servo. Check for battery vol t-
age at pi ns1, 2 and 4 of the servo. I f battery vol tage
i s not at these pi ns, repl ace the servo.
(6) Turn i gni ti on swi tch to OFF posi ti on. Check for
conti nui ty between di sconnected servo harness
4way connector pi n4 and a good ground. There
shoul d be conti nui ty. I f not OK, repai r open ci rcui t to
For compl ete PCM di agnosi s of the speed control
system, refer to the DRB scan tool and the appropri -
ate Powertrai n Di agnosti c Procedures servi ce man-
ual .
OVERSHOOT/UNDERSHOOT ON SPEED CONTROL
SET
I f the operator repeatedl y presses and rel eases the
set button wi th thei r foot off of the accel erator (a l i ft
foot set to begi n speed control operati on), the vehi cl e
may accel erate and exceed the desi red set speed by
up to 5 MPH (8 km/h) and then decel erate to l ess
than the desi red set speed before fi nal l y achi evi ng
the desi red set speed.
The Speed Control has an adapti ve strategy that
compensates for vehi cl e-to-vehi cl e vari ati ons i n speed
control cabl e l engths. When the speed control i s set
wi th the vehi cl e operators foot off of the accel erator
pedal , the speed control thi nks there i s excessi ve
speed control cabl e sl ack and adapts. I f the l i ft foot
sets are conti nual l y used, the speed control over-
shoot/undershoot condi ti on wi l l devel op.
To unl earn the overshoot/undershoot condi ti on,
the vehi cl e operator has to press and rel ease the set
button whi l e mai ntai ni ng the desi red set speed wi th
the accel erator pedal (not decel erati ng or accel erat-
i ng), and then turn the crui se control swi tch to the
OFF posi ti on (or press the CANCEL button i f
equi pped) after wai ti ng 10 seconds. Thi s procedure
must be performed approxi matel y 1015 ti mes to
compl etel y unl earn the overshoot/undershoot condi -
ti on.
SPEED CONTROL SERVO
REMOVAL
(2) Di sconnect vacuum hose at servo (Fi g. 4).
(3) Unpl ug el ectri cal connector at servo (Fi g. 4).
(4) Remove 2 mounti ng nuts hol di ng servo cabl e
sl eeve to bracket (Fi g. 4).
(5) Pul l speed control cabl e sl eeve away from servo
to expose cabl e retai ni ng cl i p.
(6) Bl ock throttl e to ful l open posi ti on.
Fig. 2 Servo Electrical Connector Location
SERVO CABLE
SERVO MOUNTING NUTS (2)
Fig. 3 Servo 4Way Harness Connector
PIN 1
PIN 2
PIN 3
(7) Remove cl i p attachi ng cabl e to servo.
(8) Remove servo from mounti ng bracket.
INSTALLATION
(1) Posi ti on servo to mounti ng bracket.
(2) Bl ock throttl e to ful l open posi ti on to al i gn hol e
i n cabl e connector wi th hol e i n servo pi n. I nstal l
cabl e-to-servo retai ni ng cl i p.
(3) I nstal l servo mounti ng nuts and ti ghten to 8.5
Nm (75 i n. l bs.).
(4) Connect vacuum hose at servo.
(5) Connect el ectri cal connector at servo.
(6) Remove throttl e bl ock.
REMOVAL
WARNING: BEFORE BEGINNING ANY AIRBAG
SYSTEM COMPONENT REMOVAL OR INSTALLA-
TION, REMOVE AND ISOLATE THE NEGATIVE (-)
CABLE FROM THE BATTERY. THIS IS THE ONLY
SURE WAY TO DISABLE THE AIRBAG SYSTEM.
THEN WAIT TWO MINUTES FOR SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE FURTHER SYSTEM
SERVICE. FAILURE TO DO THIS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE INJURY.
(1) Di sconnect and i sol ate negati ve battery cabl e.
(2) Remove ai rbag modul e. Refer to Group 8M,
Passi ve Restrai nt Systems for procedures.
(3) Remove el ectri cal connector at swi tch.
(4) Remove swi tch-to-steeri ng wheel mounti ng
screw (Fi g. 5).
(5) Remove swi tch.
INSTALLATION
(1) I nstal l swi tch and mounti ng screw.
(2) Ti ghten screw to 1.5 Nm (15 i n. l bs.) torque.
(3) I nstal l el ectri cal connector to swi tch.
(4) I nstal l ai rbag modul e. Refer to Group 8M, Pas-
si ve Restrai nt Systems for procedures.
STOP LAMP SWITCH
Refer to Stop Lamp Swi tch i n Group 5, Brakes for
removal /i nstal l ati on and adjustment procedures.
SERVO CABLE
REMOVAL
(2) 4.0L Engi ne: Usi ng fi nger pressure onl y,
remove speed control cabl e connector at throttl e body
bel l crank pi n by pushi ng connector off the bel l crank
towards the dri vers si de of vehi cl e (Fi g. 6). DO NOT
try to pull connector off perpendicular to the
bellcrank pin. Connector will be broken.
(3) 5.2L/5.9L Engi nes: Usi ng fi nger pressure onl y,
remove speed control cabl e connector at throttl e body
bel l crank by pushi ng connector rearward off the
bel l crank pi n (Fi g. 7). DO NOT try to pull connec-
tor off perpendicular to the bellcrank pin. Con-
nector will be broken.
(4) 4.0L Engi ne: Remove cabl e from cabl e gui de at
top of val ve cover.
(5) Squeeze 2 tabs on si des of speed control cabl e
at throttl e body mounti ng bracket (l ocki ng pl ate) and
push out of bracket.
Fig. 4 Speed Control Servo
SERVO CABLE
SERVO MOUNTING NUTS (2)
Fig. 5 Speed Control Switches
MOUNTINGSCREW SPEED CONTROL SWITCHES
(6) Remove servo cabl e from servo. Refer to Speed
Control Servo removal and i nstal l ati on i n thi s group.
INSTALLATION
(1) I nstal l end of cabl e to speed control servo.
Refer to Speed Control Servo removal and i nstal l a-
ti on i n thi s group.
(2) I nstal l cabl e i nto throttl e body mounti ng
bracket (snaps i n).
(3) I nstal l speed control cabl e connector at throttl e
body bel l crank pi n (snaps on).
(4) Connect negati ve battery cabl e at battery.
POWERTRAIN CONTROL MODULE
For Removal /I nstal l ati on refer to Powertrai n Con-
trol Modul e i n Group 14, Fuel I njecti on System.
VACUUM RESERVOIR
REMOVAL
(1) Di sconnect both battery cabl es at battery (neg-
ati ve cabl e fi rst).
(2) Remove battery hol ddowns.
(3) Remove battery from battery tray.
(4) Remove 5 bol ts securi ng battery tray.
(5) Pul l up battery tray and remove vacuum hose
from reservoi r (Fi g. 8).
(6) Remove 2 screws hol di ng reservoi r to battery
tray.
INSTALLATION
(1) I nstal l vacuum reservoi r. Ti ghten bol ts (screws)
(2) Connect vacuum hose at reservoi r.
(3) I nstal l battery tray mounti ng bol ts. Ti ghten to
10 Nm (90 i n. l bs.) torque.
(4) I nstal l battery.
(5) I nstal l battery hol ddown and bol ts. Ti ghten to
(6) I nstal l battery cabl e cl amp bol ts. Ti ghten to 8.5
For removal /i nstal l ati on, refer to Vehi cl e Speed
Sensor i n Group 14, Fuel System.
Fig. 6 Cable at Bell Crank4.0L Engine
BELLCRANK CABLE CONNEC- TOR PUSH SPEED CONTROL CABLE
Fig. 7 Cable at Bell Crank5.2L/5.9LV-8 Engines
VEHICLE SPEED CONTROL CABLE
PUSH
Fig. 8 Vacuum Reservoir
BATTERY TRAY VACUUM HOSE VACUUM RESERVOIR RESERVOIR ATTACHING SCREW (2) FWD
SPECIFICATIONS
TORQUE CHART
Description Torque
Servo Mounti ng Bracket-to-Servo
Nuts . . . . . . . . . . . . . . . . . . . 8.5 Nm (75 i n. l bs.)
Servo Mounti ng Bracket-to-Body
Nuts . . . . . . . . . . . . . . . . . . . . . 5 Nm (47 i n. l bs.)
Swi tch Modul e Mounti ng
Screws . . . . . . . . . . . . . . . . . . 1.5 Nm (15 i n. l bs.)
Vacuum Reservoi r Mounti ng
Bol ts . . . . . . . . . . . . . . . . . . . . 3 Nm (30 i n. l bs.)
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Thi s group covers both Left-Hand Dri ve (LHD) and
Ri ght-Hand Dri ve (RHD) versi ons of thi s model .
Whenever feasi bl e, the RHD versi ons of affected
vehi cl e components have been constructed as mi rror-
i mage of the LHD versi ons. Whi l e most of the i l l us-
trati ons used i n thi s group represent onl y the LHD
versi on, the di agnosti c and servi ce procedures out-
l i ned can general l y be appl i ed to ei ther versi on.
Excepti ons to thi s rul e have been cl earl y i denti fi ed as
LHD or RHD, i f a speci al i l l ustrati on or procedure
was/i s requi red.
The speed control system used wi th the 2.5L di esel
engi ne i s basi cal l y i denti cal to the system used wi th
gasol i ne powered engi nes. Features uni que to the
di esel engi ne wi l l be covered i n thi s secti on.
Model s equi pped wi th the 2.5L di esel engi ne do
not use a vacuum reservoi r to retai n engi ne vacuum
for speed control operati on. There are no vaccum-op-
erated speed control servos used i n vehi cl es wi th the
2.5L di esel engi ne.
The range of the speed control system operati on
i s restri cted to speeds between 56 km/h (35 MPH) to
145 km/h (90 MPH).
I nputs to the MSA that al l ow speed control oper-
ati on are from the vehi cl e speed sensor and the
Speed Control Swi tch.
si de of the dri vers ai rbag modul e. Swi tch features
are:
a. Wi thi n the two swi tch modul es, fi ve momen-
tary contact swi tches, supporti ng seven di fferent
speed control functi ons are used.
b. The outputs from these swi tches are fi l tered
i nto one i nput. The MSA 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 MSA
to determi ne whi ch swi tch functi on has been
sel ected.
c. A speed control i ndi cator l amp, l ocated on the
i nstrument panel cl uster i s energi zed by the MSA
vi a the CCD Bus. Thi s occurs when speed control
system power has been turned ON, and the engi ne
i s runni ng.
d. The two swi tch modul es are l abel ed: ON/OFF,
SET, RESUME/ACCEL, CANCEL and COAST.
on speed control swi tch functi ons and setti ng pro-
cedures. The i ndi vi dual swi tches cannot be
repai red. I f one i ndi vi dual swi tch fai l s, the swi tch
modul e must be repl aced.
TURN SIGNAL AND HAZARD WARNING SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
COMBINATION FLASHER . . . . . . . . . . . . . . . . . 1
HAZARD WARNING SYSTEM . . . . . . . . . . . . . . 1
TURN SIGNAL LAMP . . . . . . . . . . . . . . . . . . . . . 2
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH . . . . . . . . . . . . . . . . . . . . 2
TURN SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 2
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . 3
TURN SIGNAL AND HAZARD WARNING
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMBINATION FLASHER . . . . . . . . . . . . . . . . . 4
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
INTRODUCTION
components i n the turn si gnal and hazard warni ng
systems. Refer to 8W-52 - Turn Si gnal s i n Group 8W
- Wi ri ng Di agrams for compl ete ci rcui t descri pti ons
and di agrams.
TURN SIGNAL SYSTEM
Wi th the i gni ti on swi tch i n the On or Accessory
posi ti on, and the mul ti -functi on swi tch control l ever
moved up (ri ght turn) or down (l eft turn), the turn
si gnal system i s acti vated. The swi tch has a detent
posi ti on i n each di recti on that provi des turn si gnal s
wi th automati c cancel l ati on, and an i ntermedi ate
momentary posi ti on that provi des turn si gnal s onl y
unti l the mul ti -functi on swi tch l ever i s rel eased.
When the turn si gnal swi tch i s i n a detent posi -
ti on, i t i s turned off by one of two cancel l i ng cam
l obes mol ded i nto the hub of the cl ockspri ng mecha-
ni sm. When turni ng the steeri ng wheel causes one of
the cam l obes to contact a cancel actuator i n the
mul ti -functi on swi tch, the turn si gnal swi tch auto-
mati cal l y returns to the off posi ti on.
When the turn si gnal system i s acti vated, the
sel ected (ri ght or l eft) turn si gnal i ndi cator l amp,
front park/turn si gnal l amp, front si de marker l amp,
and rear tai l /stop/turn si gnal l amp bul bs wi l l fl ash.
Wi th the headl amp swi tch i n the Off posi ti on, the
front turn si gnal and front si de marker l amps fl ash
i n uni son. Wi th the headl amp swi tch i n the On posi -
ti on, the front turn si gnal and front si de marker
l amps fl ash al ternatel y.
HAZARD WARNING SYSTEM
The hazard warni ng system i s acti vated by a
swi tch button i n the mul ti -functi on swi tch. The but-
ton i s l ocated on the top of the steeri ng col umn
between the steeri ng wheel and the i nstrument
panel . The hazard warni ng swi tch button i s i denti -
fi ed wi th a doubl e tri angl e.
The hazard warni ng system i s connected to a non-
swi tched battery feed so that the system remai ns
functi onal , regardl ess of the i gni ti on swi tch posi ti on.
Push the swi tch button i n to acti vate the hazard
warni ng system, and push i n on the button agai n to
turn the system off.
When the hazard warni ng system i s acti vated, the
ri ght and l eft turn si gnal i ndi cators, front park/turn
si gnal l amps, front si de marker l amps, and rear tai l /
stop/turn si gnal l amps wi l l fl ash.
COMBINATION FLASHER
The combi nati on fl asher i s a smart rel ay that func-
ti ons as both the turn si gnal system and hazard
warni ng system fl asher. The combi nati on fl asher i s
desi gned to handl e the current fl ow requi rements of
the factory-i nstal l ed l i ghti ng.
ZG TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1
I f suppl emental l i ghti ng i s added to the turn si gnal
l amp ci rcui ts, such as when towi ng a trai l er wi th
l i ghts, the combi nati on fl asher wi l l automati cal l y
compensate. Thi s al l ows the fl ash rate to remai n the
same, regardl ess of el ectri cal l oad i ncreases. How-
ever, i f a bul b fai l s i n the turn si gnal l amp ci rcui ts,
the fl ash rate of the remai ni ng bul bs i n that ci rcui t
wi l l i ncrease to 120 fl ashes-per-mi nute, or hi gher.
Whi l e the combi nati on fl asher shares the termi nal
ori entati on (footpri nt) of a I nternati onal Standards
Organi zati on (I SO)-type rel ay, the i nternal ci rcui try
i s much di fferent. The combi nati on fl asher contai ns
acti ve el ectroni c i ntegrated ci rcui try el ements. Do not
substi tute any other rel ay for the combi nati on
fl asher.
Because of the acti ve el ectroni c el ements wi thi n
the combi nati on fl asher, i t cannot be tested wi th con-
venti onal automoti ve el ectri cal test equi pment. I f the
combi nati on fl asher i s bel i eved to be faul ty, test the
turn si gnal and hazard warni ng system ci rcui ts as
descri bed i n thi s group. Then repl ace the combi na-
ti on fl asher wi th a known good uni t to confi rm sys-
tem operati on.
The combi nati on fl asher cannot be repai red and, i f
faul ty, i t must be repl aced.
TURN SIGNAL SWITCH AND HAZARD WARNING
SWITCH
The turn si gnal and hazard warni ng swi tches are
i ntegral to the mul ti -functi on swi tch assembl y. The
mul ti -functi on swi tch assembl y i s secured to the l eft
si de of the steeri ng col umn (Fi g. 1). Thi s swi tch con-
tai ns ci rcui try for the fol l owi ng functi ons:
Turn si gnal s
Hazard warni ng
Headl amp beam sel ecti on
Headl amp opti cal horn
Wi ndshi el d wi pers
Wi ndshi el d washers.
The i nformati on contai ned i n thi s group addresses
onl y the mul ti -functi on swi tch functi ons for the turn
si gnal and hazard warni ng ci rcui ts. For i nformati on
rel ati ve to the other swi tch functi ons, refer to the
proper group. However, the mul ti -functi on swi tch
cannot be repai red. I f any functi on of the mul ti -func-
ti on swi tch i s faul ty, or i f the swi tch i s damaged, the
enti re swi tch assembl y must be repl aced.
The turn si gnal i ndi cator l amps are l ocated i n the
i nstrument cl uster. They fl ash wi th the exteri or turn
si gnal l amps to gi ve the dri ver a vi sual i ndi cati on
that a turn si gnal or the hazard warni ng system i s
operati ng. For di agnosi s and servi ce of these l amps,
refer to Group 8E - I nstrument Panel Systems.
Model s equi pped wi th an opti onal Vehi cl e I nforma-
ti on Center (VI C) have a turn si gnal on warni ng
feature. The VI C modul e moni tors the turn si gnal
ci rcui t from the combi nati on fl asher. The VI C modul e
wi l l di spl ay the message, Turn Si gnal On, and send a
request to the Body Control Modul e (BCM) on the
Chrysl er Col l i si on Detecti on (CCD) data bus network
for si x chi me tones, i f a turn si gnal remai ns acti vated
for more than approxi matel y one-hal f mi l e of dri vi ng.
Refer to Group 8E - I nstrument Panel Systems for
di agnosi s and servi ce of the VI C modul e. Refer to the
nosi s and servi ce of the BCM or the CCD data bus.
TURN SIGNAL LAMP
The exteri or l amps i n the turn si gnal and hazard
warni ng ci rcui ts i ncl ude the front park/turn si gnal ,
the front si de marker, and the rear tai l /stop/turn si g-
nal . For di agnosi s and servi ce of these l amps, refer to
Group 8L - Lamps.
INTRODUCTION
When di agnosi ng the turn si gnal or hazard warn-
i ng ci rcui ts, remember that hi gh generator output
can burn out bul bs rapi dl y and repeatedl y. I f thi s i s a
probl em on the vehi cl e bei ng di agnosed, refer to
Group 8C - Chargi ng System for further di agnosi s of
a possi bl e generator overchargi ng condi ti on.
Fig. 1 Multi-Function Switch
WINDSHIELD WASHER BUT- TON CONTROL STALK HAZARD WARNING BUTTON WINDSHIELD WIPER CON- TROL MULTI-FUNCTION SWITCH
8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS ZG
INJURY.
TURN SIGNAL AND HAZARD WARNING SYSTEMS
8W-52 - Turn Si gnal s i n Group 8W - Wi ri ng Di a-
grams.
INJURY.
Actuate the turn si gnal l ever or the hazard warni ng
button. Observe the turn si gnal i ndi cator l amp(s) i n
the i nstrument cl uster. I f the fl ash rate i s very hi gh,
check for a turn si gnal bul b that i s not l i t or i s very
di ml y l i t. Repai r the ci rcui ts to that l amp or repl ace
the faul ty bul b, as requi red. Test the operati on of the
turn si gnal and hazard warni ng systems agai n. I f the
turn si gnal i ndi cator(s) fai l to l i ght, go to Step 2.
Check the turn si gnal fuse i n the juncti on bl ock
and/or the hazard warni ng fuse i n the Power Di stri -
buti on Center (PDC). I f OK, go to Step 3. I f not OK,
repai r the shorted ci rcui t or component as requi red
and repl ace the faul ty fuse(s).
(3) Turn the i gni ti on swi tch to the On posi ti on to
check for battery vol tage at the turn si gnal fuse i n
the juncti on bl ock; or, l eave the i gni ti on swi tch i n the
Off posi ti on to check for battery vol tage at the haz-
ard warni ng fuse i n the PDC. I f OK, go to Step 4. I f
not OK, repai r the open ci rcui t as requi red.
Unpl ug the combi nati on fl asher from the juncti on
bl ock and repl ace i t wi th a known good uni t. Connect
the battery negati ve cabl e. Test the operati on of the
turn si gnal and hazard warni ng systems. I f OK, di s-
card the faul ty combi nati on fl asher. I f not OK,
remove the test fl asher and go to Step 5.
Check for battery vol tage at the fused i gni ti on swi tch
output ci rcui t cavi ty for the combi nati on fl asher i n
the juncti on bl ock. I f OK, go to Step 6. I f not OK,
repai r the open ci rcui t to the turn si gnal fuse as
requi red.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty for the combi nati on fl asher i n the juncti on
ci rcui t to the hazard warni ng fuse as requi red.
cabl e. Check for conti nui ty between the ground ci r-
cui t cavi ty for the combi nati on fl asher i n the juncti on
bl ock and a good ground. There shoul d be conti nui ty.
I f OK, go to Step 8. I f not OK, repai r the ci rcui t to
(8) Unpl ug the mul ti -functi on swi tch wi re harness
connector as descri bed i n thi s group. Check for con-
ti nui ty between the combi nati on fl asher hazard si g-
nal ci rcui t cavi ti es i n the juncti on bl ock and i n the
mul ti -functi on swi tch wi re harness connector. There
(9) Check for conti nui ty between the combi nati on
fl asher turn si gnal ci rcui t cavi ti es i n the juncti on
bl ock and i n the mul ti -functi on swi tch wi re harness
connector. There shoul d be conti nui ty. I f OK, test the
mul ti -functi on swi tch as descri bed i n thi s group. I f
MULTI-FUNCTION SWITCH
Perform the di agnosi s of the hazard warni ng
and/or turn si gnal systems as descri bed i n thi s group
before testi ng the mul ti -functi on swi tch. For ci rcui t
descri pti ons and di agrams, refer to 8W-52 - Turn Si g-
nal s i n Group 8W - Wi ri ng Di agrams.
INJURY.
connector as descri bed i n thi s group.
(2) Usi ng an ohmmeter, perform the swi tch conti -
nui ty checks at the swi tch termi nal s as shown i n the
Mul ti -Functi on Swi tch Conti nui ty chart (Fi g. 2).
(3) I f the swi tch fai l s any of the conti nui ty checks,
repl ace the faul ty swi tch. I f the swi tch i s OK, repai r
the l i ghti ng ci rcui ts as requi red.
COMBINATION FLASHER
INJURY.
cabl e.
3).
tri m.
(6) Unpl ug the combi nati on fl asher from the junc-
ti on bl ock.
(7) I nstal l the combi nati on fl asher by al i gni ng the
fl asher termi nal s wi th the cavi ti es i n the juncti on
bl ock and pushi ng the fl asher fi rml y i nto pl ace.
Fig. 2 Multi-Function Switch Continuity
VIEW FROM TERMINAL CASE
(9) Test the fl asher operati on.
fuse access panel .
MULTI-FUNCTION SWITCH
INJURY.
cabl e.
(2) I f the vehi cl e i s so equi pped, remove the ti l t
steeri ng col umn l ever.
bezel s.
bl ocker and steeri ng col umn cover to the i nstrument
panel (Fi g. 4).
panel .
fl at-bl aded tool , gentl y pry the edges of the knee
bl ocker away from the i nstrument panel at the snap
cl i p retai ner l ocati ons (Fi g. 4).
(8) Remove the knee bl ocker and steeri ng col umn
cover from the vehi cl e.
(9) Remove both the upper and l ower shrouds from
the steeri ng col umn (Fi g. 5).
(10) Remove the l ower fi xed col umn shroud.
(11) Loosen the steeri ng col umn upper bracket
nuts. Do not remove the nuts.
(12) Move the upper fi xed col umn shroud to gai n
access to the rear of the mul ti -functi on swi tch (Fi g.
6).
(13) Remove the mul ti -functi on swi tch tamper
proof mounti ng screws (a Snap On tamper proof torx
bi t TTXR20B2 or equi val ent i s requi red).
Fig. 5 Steering Column Shrouds Remove/Install-
Typical
Fig. 6 Multi-Function Switch Connector -Typical
STEERING COL- UMN ASSY. MULTI-FUNCTION SWITCH CONNEC- TOR TURN SIGNAL SWITCH AND LEVER
(14) Gentl y pul l the swi tch away from the col umn.
Loosen the wi re harness connector screw. The screw
wi l l remai n i n the wi re harness connector.
mul ti -functi on swi tch.
Ti ghten the fasteners as fol l ows:
Mul ti -functi on swi tch wi re harness connector
screw - 2 Nm (17 i n. l bs.)
Mul ti -functi on swi tch retai ni ng screws - 2 Nm
(17 i n. l bs.)
Steeri ng col umn upper bracket nuts - 12 Nm
(110 i n. l bs.).
WIPER AND WASHER SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
INTERMITTENT WIPE RELAY . . . . . . . . . . . . . . 4
REAR WIPER AND WASHER SYSTEM . . . . . . . 2
WASHER NOZZLE AND PLUMBING . . . . . . . . . 4
WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 4
WASHER RESERVOIR . . . . . . . . . . . . . . . . . . . . 4
WINDSHIELD WASHER SYSTEM . . . . . . . . . . . 1
WINDSHIELD WIPER SYSTEM . . . . . . . . . . . . . 1
WIPER ARM AND BLADE . . . . . . . . . . . . . . . . . 2
WIPER LINKAGE AND PIVOT . . . . . . . . . . . . . . 2
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . 2
WIPER SWITCH AND WASHER SWITCH . . . . . . 3
INTERMITTENT WIPE RELAY . . . . . . . . . . . . . . 8
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . 6
WIPER SWITCH AND WASHER SWITCH . . . . . . 7
WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 5
INTERMITTENT WIPE RELAY . . . . . . . . . . . . . 12
WASHER PUMP AND RESERVOIR . . . . . . . . . 14
WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WIPER BLADE AND ELEMENT . . . . . . . . . . . . . 9
WIPER LINKAGE AND PIVOT . . . . . . . . . . . . . 12
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 11
WIPER SWITCH AND WASHER SWITCH . . . . . 13
GENERAL INFORMATION
INTRODUCTION
components i n the wi per and washer systems. Refer
to 8W-53 - Wi pers i n Group 8W - Wi ri ng Di agrams
for compl ete ci rcui t descri pti ons and di agrams.
WINDSHIELD WIPER SYSTEM
An i ntermi ttent wi ndshi el d wi per system i s stan-
dard equi pment. Thi s system l ets the dri ver sel ect
from ei ther of two wi per speeds, or the i ntermi ttent
wi pe mode. The i ntermi ttent wi pe mode i s provi ded
by del ay l ogi c and rel ay control ci rcui try contai ned
wi thi n the Body Control Modul e (BCM), and an
i ntermi ttent wi pe rel ay.
The i ntermi ttent wi pe mode del ay ti mes are speed
sensi ti ve. Above about si xteen ki l ometers-per-hour
(ten mi l es-per-hour) the del ay i s dri ver adjustabl e
from about one-hal f second to about ei ghteen sec-
onds. Bel ow about si xteen ki l ometers-per-hour (ten
mi l es-per-hour) the BCM doubl es the del ay ti me, or
provi des del ays of about one second to about thi rty-
si x seconds.
Model s equi pped wi th the opti onal automati c head-
l amp system have a programmabl e feature i n the
BCM that wi l l energi ze the headl amps automati cal l y,
whenever the wi ndshi el d wi pers are turned on. Refer
to the proper Di agnosti c Procedures manual for more
i nformati on on enabl i ng or di sabl i ng thi s feature.
The wi ndshi el d wi pers wi l l operate onl y when the
i gni ti on swi tch i s i n the Accessory or On posi ti ons. A
ci rcui t breaker l ocated i n the juncti on bl ock protects
the ci rcui try of the wi ndshi el d wi per system. Refer to
the owners manual for more i nformati on on the
wi ndshi el d wi per system control s and operati on.
WINDSHIELD WASHER SYSTEM
A el ectri cal l y operated wi ndshi el d washer system i s
standard equi pment. A reservoi r i n the engi ne com-
partment hol ds the washer fl ui d, whi ch i s pressur-
i zed by a pump when the wi ndshi el d washer (mul ti -
functi on) swi tch i s actuated. The wi ndshi el d washer
pump feeds the pressuri zed washer fl ui d through the
washer system pl umbi ng to the wi ndshi el d washer
nozzl es.
Vehi cl es wi th the opti onal Vehi cl e I nformati on Cen-
ter (VI C) have a l ow washer fl ui d warni ng feature
that wi l l warn the dri ver when the washer fl ui d l evel
needs to be checked. Refer to Group 8E - I nstrument
Panel Systems for more i nformati on on thi s feature.
ZG WIPER AND WASHER SYSTEMS 8K - 1
The washers wi l l operate onl y when the i gni ti on
swi tch i s i n the Accessory or On posi ti ons. A ci rcui t
breaker l ocated i n the juncti on bl ock protects the ci r-
cui try of the washer system. Refer to the owners
manual for more i nformati on on the wi ndshi el d
washer system control s and operati on.
REAR WIPER AND WASHER SYSTEM
A rear wi per and washer system i s standard equi p-
ment on thi s model . The rear wi per system provi des
the fol l owi ng operati ng modes:
I ntermi ttent wi pe wi th a fi ve to ei ght second
del ay between sweeps.
Conti nuous fi xed-cycl e wi pe.
A park mode that operates the wi per motor unti l
the bl ade reaches i ts park posi ti on when the rear
wi per swi tch or i gni ti on swi tch i s pl aced i n the Off
posi ti on, or when the l i ftgate or l i ftgl ass (i f the vehi -
cl e i s so equi pped) i s opened.
A rear washer mode that provi des two or three
wi per bl ade sweeps before returni ng to the previ ousl y
sel ected rear wi per swi tch mode.
A si ngl e swi tch i n the i nstrument panel i nboard
swi tch pod control s both the rear wi per and washer
functi ons. The rear washer system shares the reser-
voi r of the wi ndshi el d washer system, but has i ts
own dedi cated washer pump and pl umbi ng.
The rear wi per and washer systems wi l l operate
onl y when the i gni ti on swi tch i s i n the Accessory or
On posi ti ons, and when the l i ftgate and/or opti onal
l i ftgl ass are cl osed. A fuse i n the juncti on bl ock pro-
tects the ci rcui try of both the rear wi per and washer
systems.
The rear wi per motor ci rcui try moni tors the l i ft-
gate ajar swi tch and opti onal l i ftgl ass ajar swi tch ci r-
cui ts. Refer to Group 8Q - Vehi cl e Theft/Securi ty
Systems for more i nformati on on the l i ftgate ajar and
l i ftgl ass ajar swi tch ci rcui ts. Refer to the owners
manual for more i nformati on on the rear wi per and
washer system control s and operati on.
WIPER ARM AND BLADE
Al l Grand Cherokee model s have two 50.8-centi me-
ter (20-i nch) wi ndshi el d wi per bl ades wi th repl ace-
abl e rubber el ements (squeegees). The rear wi per
uses a si ngl e 30.48-centi meter (12-i nch) wi per bl ade
wi th a repl aceabl e rubber el ement (squeegee).
Cauti on shoul d be exerci sed to protect the rubber
squeegees from any petrol eum-based cl eaners or con-
tami nants, whi ch wi l l rapi dl y deteri orate the rubber.
I f the squeegees are damaged, worn, or contami -
nated, they must be repl aced.
Wi per squeegees exposed to the el ements for a l ong
ti me tend to l ose thei r wi pi ng effecti veness. Peri odi c
cl eani ng of the squeegees i s suggested to remove
deposi ts of sal t and road fi l m. The wi per bl ades,
arms, and wi ndshi el d or rear gl ass shoul d be cl eaned
wi th a sponge or cl oth and wi ndshi el d washer fl ui d, a
mi l d detergent, or a non-abrasi ve cl eaner. I f the
squeegees conti nue to streak or smear, they shoul d
be repl aced.
The bl ades are mounted to spri ng-l oaded wi per
arms. The spri ng tensi on of the wi per arms control s
the pressure appl i ed to the bl ades on the gl ass. The
wi ndshi el d wi per arms are secured by an i ntegral
l atch to the two wi per pi vots on the cowl pl enum cov-
er/gri l l e panel at the base of the wi ndshi el d. The rear
wi per arm i s secured by a nut under the wi per arm
pi vot-end cover di rectl y to the rear wi per motor out-
put shaft on the l i ftgate panel .
The wi per arms and bl ades cannot be adjusted or
repai red. I f faul ty or damaged, they must be
repl aced.
WIPER LINKAGE AND PIVOT
The wi per l i nkage and pi vot modul e i s secured
wi th screws to the cowl pl enum panel beneath the
cowl pl enum cover/gri l l e panel . The wi per motor i s
secured wi th screws to the center of the l i nkage and
pi vot modul e bracket. The wi per pi vots are secured
to the ends of the modul e bracket.
The two wi per pi vot crank arms and the wi per
motor crank arm each have bal l studs on thei r ends.
The motor crank arm bal l stud i s the l onger of the
three. Two dri ve l i nks connect the motor crank arm
to the pi vot crank arms.
The passenger si de dri ve l i nk has a pl asti c socket-
type bushi ng on each end. The dri ver si de dri ve l i nk
has a pl asti c socket-type bushi ng on one end, and a
pl asti c sl eeve-type bushi ng on the other end. The
socket-type bushi ng on one end of each dri ve l i nk i s
fi t over the bal l stud on the crank arm of i ts respec-
ti ve pi vot. The dri ver si de dri ve l i nk sl eeve-type
bushi ng end i s then fi t over the motor crank arm bal l
stud, and the other socket-type bushi ng of the pas-
senger si de dri ve l i nk i s snap-fi t over the exposed
end of the motor crank arm bal l stud.
The wi per l i nkage, pi vots, bushi ngs, and mounti ng
bracket are onl y servi ced as a compl ete uni t. I f any
part of thi s assembl y i s faul ty or damaged, the enti re
wi per l i nkage and pi vots modul e must be repl aced.
The wi per motor and wi per motor crank arm are ser-
vi ced separatel y.
WIPER MOTOR
FRONT
The two-speed permanent magnet wi per motor has
an i ntegral transmi ssi on and park swi tch. The motor
i s secured to the wi per l i nkage and pi vot modul e
bracket wi th three screws. The wi per motor output
shaft passes through a hol e i n the modul e bracket,
8K - 2 WIPER AND WASHER SYSTEMS ZG
where a nut secures the wi per motor crank arm to
the motor output shaft.
Wi per speed i s control l ed by current fl ow to the
proper set of brushes. The wi per motor compl etes i ts
wi pe cycl e when the wi ndshi el d wi per (mul ti -func-
ti on) swi tch i s turned to the Off posi ti on, and parks
the bl ades i n the l owest porti on of the wi pe pattern.
The wi ndshi el d wi per motor cannot be repai red. I f
faul ty or damaged, the enti re wi per motor assembl y
must be repl aced. The motor crank arm and the l i nk-
age and pi vots modul e are avai l abl e for servi ce.
REAR
The rear wi per motor i s secured wi th two bol ts and
nuts to a bracket on the l i ftgate i nner panel , bel ow
the rear gl ass and behi nd the l i ftgate tri m panel . The
motor output shaft passes through the l i ftgate outer
panel where a gasket, bezel , and nut, seal and secure
the uni t to the l i ftgate outer panel . The rear wi per
arm i s secured di rectl y to the motor output shaft
wi th a nut.
The rear wi per motor uni t contai ns i ntegral el ec-
troni c control s that provi de the fol l owi ng operati ng
modes:
I ntermi ttent wi pe wi th a fi ve to ei ght second
del ay between sweeps.
Conti nuous fi xed-cycl e wi pe.
A park mode that operates the wi per motor unti l
the bl ade reaches i ts park posi ti on when the rear
wi per swi tch or i gni ti on swi tch i s pl aced i n the Off
posi ti on, or when the l i ftgate or l i ftgl ass (i f the vehi -
cl e i s so equi pped) i s opened.
A rear washer mode that provi des two or three
wi per bl ade sweeps before returni ng to the previ ousl y
sel ected rear wi per swi tch mode.
The rear wi per motor cannot be repai red. I f faul ty
or damaged, the enti re rear wi per motor assembl y
must be repl aced.
WIPER SWITCH AND WASHER SWITCH
FRONT
The wi ndshi el d wi per and washer swi tches are
contai ned i n the mul ti -functi on swi tch assembl y (Fi g.
1). The mul ti -functi on swi tch assembl y i s secured to
the l eft si de of the steeri ng col umn.
The mul ti -functi on swi tch contai ns ci rcui try for the
fol l owi ng functi ons:
Turn si gnal s
Hazard warni ng
Headl amp beam sel ecti on
Headl amp opti cal horn
Wi ndshi el d wi pers
Wi ndshi el d washers.
The i nformati on contai ned i n thi s group addresses
onl y the swi tch functi ons for the wi ndshi el d wi per
and washer systems. For i nformati on rel ati ve to the
other swi tch functi ons, refer to the proper group.
However, the mul ti -functi on swi tch cannot be
repai red. I f any functi on of the mul ti -functi on swi tch
i s faul ty, or i f the swi tch i s damaged, the enti re
swi tch assembl y must be repl aced.
REAR
The si ngl e two-functi on rear wi per and washer
swi tch i s part of the i nboard swi tch pod uni t, whi ch
i s l ocated on the i nstrument panel just i nboard of the
steeri ng col umn. The rear wi per and washer swi tch
control s the rear wi per and washer functi ons.
The sl i di ng-type swi tch features a detent i n the On
and Del ay posi ti ons. The swi tch knob i s depressed to
acti vate the rear washer system. Both the rear wi per
and rear washer motors wi l l operate conti nuousl y for
as l ong as the swi tch i s hel d i n the momentary Wash
posi ti on.
The rear wi per and washer swi tch cannot be
repai red and, i f faul ty or damaged, the enti re i nboard
swi tch pod uni t must be repl aced.
BODY CONTROL MODULE
supports and control s are the speed sensi ti ve i nter-
mi ttent wi pe, pul se wi pe, and wi pe-after-wash
Fig. 1 Multi-Function Switch
WINDSHIELD WASHER BUT- TON CONTROL STALK HAZARD WARNING BUTTON WINDSHIELD WIPER CON- TROL MULTI-FUNCTION SWITCH
modes. On model s wi th the opti onal automati c head-
l amps, the BCM can be programmed to automati cal l y
turn on the headl amps when the wi ndshi el d wi pers
are turned on. Refer to the proper Body Di agnosti c
Procedures manual for more i nformati on on enabl i ng
or di sabl i ng thi s feature.
The BCM i s programmed to energi ze or de-energi ze
the i ntermi ttent wi pe rel ay i n response to certai n
i nputs from the mul ti -functi on swi tch and the wi nd-
shi el d wi per motor park swi tch. For the speed sensi -
ti ve i ntermi ttent wi pe feature, the BCM al so uses an
i nput from the vehi cl e speed sensor, whi ch i s recei ved
on the CCD data bus from the Powertrai n Control
Modul e (PCM).
INTERMITTENT WIPE RELAY
The i ntermi ttent wi pe 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 (or footpri nt) i s di fferent, 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 i ntermi ttent wi pe rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the wi nd-
shi el d wi per motor or wi per motor park swi tch when
the rel ay coi l i s grounded by the Body Control Mod-
ul e (BCM) i n response to i nputs from the wi ndshi el d
wi per (mul ti -functi on) swi tch. See the Di agnosi s and
the i ntermi ttent wi pe rel ay.
The i ntermi ttent wi pe 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 i ntermi ttent wi pe rel ay cannot be repai red
and, i f faul ty or damaged, i t must be repl aced.
WASHER RESERVOIR
A si ngl e washer fl ui d reservoi r i s used for both the
front and rear washer systems. The washer fl ui d res-
ervoi r i s secured to the l eft front i nner fender shi el d,
behi nd the front wheel house i n the engi ne compart-
ment.
Each washer pump and motor uni t has a threaded
ni ppl e, whi ch i s i nstal l ed through a rubber grommet
seal i nserted i n a hol e near the bottom of the reser-
voi r. A pl asti c nut and washer that secures the
washer pump ni ppl e from the i nsi de of the reservoi r,
can be accessed through the reservoi r fi l l er neck.
The reservoi r al so has a provi si on for a washer
fl ui d l evel sensor. The sensor mounts i n a hol e i n the
rearward faci ng si de of the reservoi r that i s nearest
to the dash panel . Refer to Group 8E - I nstrument
Panel Systems for di agnosi s of the sensor.
The washer reservoi r, fi l l er cap, and sensor are
each avai l abl e for servi ce.
WASHER PUMP
The washer pumps and motors are mounted near
the bottom of the washer reservoi r. A threaded ni ppl e
on the pump housi ng passes through a rubber grom-
met seal i nstal l ed i n a hol e near the bottom of the
reservoi r. A pl asti c nut and washer secures the
washer pump ni ppl e from the i nsi de of the reservoi r.
A permanentl y l ubri cated and seal ed motor i s cou-
pl ed to a rotor-type pump. Washer fl ui d i s gravi ty-fed
from the reservoi r to the pump. When the motor i s
energi zed, the pump pressuri zes the washer fl ui d
and forces i t through the pl umbi ng to the nozzl es.
The washer pump and motor uni t cannot be
repai red. I f faul ty, the enti re washer pump and
motor uni t must be repl aced.
WASHER NOZZLE AND PLUMBING
FRONT
Pressuri zed washer fl ui d i s fed through a si ngl e
hose, attached to a barbed ni ppl e on the front washer
pump. The hose i s routed to a tee fi tti ng l ocated i n
the cowl pl enum area, beneath the cowl pl enum cov-
er/gri l l e panel . Hoses from the tee fi tti ng are routed
to the two nozzl es, whi ch are snapped i nto openi ngs
i n the cowl pl enum cover/gri l l e panel , bel ow the
wi ndshi el d.
The two fl ui di c washer nozzl es are not adjustabl e.
The nozzl es and hose fi tti ngs cannot be repai red and,
i f faul ty or damaged, they must be repl aced.
REAR
Pressuri zed washer fl ui d i s fed through a si ngl e
hose, attached to a barbed ni ppl e on the rear washer
pump. The hose i s routed from the front of the vehi -
cl e to the l i ftgate wi th the l eft si de body wi re har-
ness.
Above the l i ftgate openi ng the hose connects to a
check val ve, whi ch prevents washer fl ui d drai n-back
or si phoni ng from occurri ng. From the check val ve,
another si ngl e hose i s routed through hol es and
grommets i n the upper l i ftgate openi ng panel and the
l i ftgate i nner panel to the washer nozzl e. The washer
nozzl e snaps i nto a hol e i n the l i ftgate outer panel ,
above the l i ftgate gl ass.
The washer nozzl e i s not adjustabl e. The nozzl e,
check val ve, and hose fi tti ngs cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
WIPER SYSTEM
FRONT
I f the probl em bei ng di agnosed i nvol ves onl y the
pul se wi pe or wi pe-after-wash modes, see the Washer
System di agnosi s i n thi s group. For ci rcui t descri p-
ti ons and di agrams, refer to 8W-53 - Wi pers i n Group
INJURY.
cabl e. Remove the ci rcui t breaker from the juncti on
bl ock. Connect the battery negati ve cabl e. Turn the
vol tage at the battery si de of the ci rcui t breaker. I f
OK, rei nstal l the ci rcui t breaker and go to Step 2. I f
not OK, repai r the ci rcui t from the i gni ti on swi tch as
requi red.
I nstal l the ci rcui t breaker. Connect the battery nega-
ti ve cabl e. Turn the i gni ti on swi tch to the On posi -
ti on. Check for battery vol tage at the wi per system
si de of the ci rcui t breaker. I f OK, go to Step 3. I f not
OK, repl ace the faul ty ci rcui t breaker.
Unpl ug the mul ti -functi on swi tch wi re harness con-
nector. Connect the battery negati ve cabl e. Turn the
vol tage at the fused i gni ti on swi tch output (F86) ci r-
cui t cavi ty of the mul ti -functi on swi tch wi re harness
connector. I f OK, go to Step 4. I f not OK, repai r the
open ci rcui t to the ci rcui t breaker as requi red.
(4) I f the probl em bei ng di agnosed i nvol ves onl y
the i ntermi ttent wi pe feature, go to Step 5. I f the
probl em bei ng di agnosed i nvol ves al l wi per modes, or
onl y the Low and/or Hi gh speed modes, go to Step 7.
Unpl ug the whi te 24-way Body Control Modul e
between the wi per swi tch mode sense cavi ti es of the
mul ti -functi on swi tch wi re harness connector and the
BCM whi te 24-way wi re harness connector. There
(6) Unpl ug the bl ack 24-way BCM wi re harness
connector. Check for conti nui ty between the wi nd-
shi el d wi per swi tch si gnal cavi ti es of the mul ti -func-
ti on swi tch wi re harness connector and the BCM
bl ack 24-way wi re harness connector. There shoul d
be conti nui ty. I f OK, see the I ntermi ttent Wi pe Rel ay
di agnosi s i n thi s group. I f not OK, repai r the open
(7) Check for conti nui ty between the two wi per
swi tch l ow speed output ci rcui t cavi ti es of the mul ti -
functi on swi tch wi re harness connector. There shoul d
be conti nui ty. I f OK, go to Step 8. I f not OK, repai r
(8) Test the wi per swi tch, as descri bed i n thi s
group. I f the swi tch tests OK, pl ug i n the mul ti -func-
ti on swi tch wi re harness connector and go to Step 9.
I f not OK, repl ace the faul ty swi tch and test the
wi per system operati on. I f sti l l not OK, go to Step 9.
Move the wi per modul e far enough to access the
wi per motor wi re harness connector, as descri bed i n
thi s group. Measure the resi stance between the
ground ci rcui t cavi ty of the wi per motor wi re harness
connector and a good ground. The meter shoul d read
zero ohms. I f OK, go to Step 10. I f not OK, repai r the
ci rcui t to ground as requi red.
i gni ti on swi tch to the On posi ti on. Pl ace the mul ti -
functi on swi tch i n the posi ti ons i ndi cated i n the tests
bel ow, and check for battery vol tage at the wi per
motor wi re harness connector.
(a) Check for battery vol tage at the fused i gni -
ti on swi tch output ci rcui t cavi ty of the wi per motor
wi re harness connector wi th the wi per swi tch i n
any posi ti on. I f OK, go to Step 2. I f not OK, repai r
(b) Check for battery vol tage at the wi per swi tch
l ow speed output ci rcui t cavi ty of the wi per motor
the Low posi ti on. I f OK, go to Step 3. I f not OK,
(c) Check for battery vol tage at the wi per swi tch
hi gh speed output ci rcui t cavi ty of the wi per motor
the Hi gh posi ti on. I f OK, go to Step 4. I f not OK,
(d) Check for battery vol tage at the wi per park
swi tch sense ci rcui t cavi ty of the wi per motor wi re
harness connector wi th the wi per swi tch i n the
Low or Hi gh posi ti on, then move the swi tch to the
Off posi ti on. The meter shoul d swi tch between bat-
tery vol tage and zero vol ts whi l e the wi pers are
cycl i ng. The meter shoul d read battery vol tage
when the swi tch i s moved to the Off posi ti on unti l
the wi pers park, and then read a steady zero vol ts.
I f not OK, repl ace the faul ty wi per motor.
REAR
8W-53 - Wi pers i n Group 8W - Wi ri ng Di agrams.
INJURY.
to Step 2. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
output ci rcui t cavi ty of the rear wi per swi tch wi re
harness connector. I f OK, go to Step 3. I f not OK,
Remove and test the rear wi per swi tch, as descri bed
i n thi s group. I f OK, go to Step 4. I f not OK, repl ace
the faul ty swi tch.
(4) Remove the l i ftgate i nner tri m panel . Measure
the resi stance between the ground ci rcui t cavi ty of
the rear wi per motor wi re harness connector and a
good ground. The meter shoul d read zero ohms. I f
OK, go to Step 5. I f not OK, repai r the ci rcui t to
(5) Check for conti nui ty between the l i ftgate ajar
swi tch sense cavi ty of the rear wi per motor wi re har-
conti nui ty wi th l i ftgate and/or l i ftgl ass (i f the vehi cl e
i s so equi pped) open, and no conti nui ty wi th the l i ft-
gate and l i ftgl ass (i f the vehi cl e i s so equi pped)
cl osed. I f OK, go to Step 6. I f not OK, repai r the l i ft-
gate and/or l i ftgl ass ajar ci rcui t or swi tch as
requi red.
(6) Pl ug i n the rear wi per swi tch wi re harness con-
nector. Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Pl ace the rear
wi per swi tch i n the Wi pe posi ti on. Check for battery
vol tage at the rear wi per motor control ci rcui t cavi ty
of the rear wi per motor wi re harness connector.
Repeat the test for the rear wi per motor control
(i ntermi ttent) ci rcui t cavi ty wi th the rear wi per
swi tch i n the I ntermi ttent posi ti on, then at the rear
washer motor control ci rcui t cavi ty wi th the rear
wi per swi tch i n the Wash posi ti on. I n each case, the
meter shoul d read battery vol tage. I f OK, repl ace the
faul ty rear wi per motor. I f not OK, repai r the open
ci rcui t(s) as requi red.
WASHER SYSTEM
FRONT
washer pump or wi pe-after-wash feature. I f the
washer pump operates, but no washer fl ui d i s emi t-
ted from the washer nozzl es, be certai n to check the
fl ui d l evel i n the reservoi r. Check for i ce or other for-
ei gn materi al i n the reservoi r, and for pi nched, di s-
connected, broken, or i ncorrectl y routed washer
system pl umbi ng. For ci rcui t descri pti ons and di a-
grams, refer to 8W-53 - Wi pers i n Group 8W - Wi ri ng
Di agrams.
INJURY.
Turn the wi per swi tch to the Low or Hi gh speed posi -
ti on. Check whether the wi pers operate. I f OK, go to
Step 2. I f not OK, see the Wi per System di agnosi s i n
thi s group.
(2) Turn the wi per swi tch to the Off posi ti on.
Depress the washer swi tch for l ess than one-hal f sec-
ond. The wi pers shoul d operate for one sweep cycl e
and then park. Depress the washer swi tch for more
than one-hal f second. The washer pump shoul d oper-
ate and the wi pers shoul d operate for two sweep
cycl es after the swi tch i s rel eased before they park. I f
the wi pers are OK, but the washers are not, go to
Step 3. I f the washers are OK, but the wi pers are
not, go to Step 5.
Unpl ug the front washer pump wi re harness connec-
tor. Measure the resi stance between the ground ci r-
cui t cavi ty of the front washer pump wi re harness
ground ci rcui t as requi red.
i gni ti on swi tch to the On posi ti on. Depress the
washer swi tch. Measure the vol tage at the washer
swi tch output ci rcui t cavi ty of the front washer pump
wi re harness connector. The meter shoul d read bat-
tery vol tage. I f OK, repl ace the faul ty pump. I f not
OK, repai r the open ci rcui t as requi red.
Unpl ug the whi te 24-way wi re harness connector
from the Body Control Modul e (BCM). Connect the
battery negati ve cabl e. Turn the i gni ti on swi tch to
the On posi ti on. Depress the washer swi tch. Check
for battery vol tage at the washer swi tch output ci r-
cui t cavi ty of the whi te 24-way BCM wi re harness
connector. I f OK, see the I ntermi ttent Wi pe Rel ay
REAR
washer pump. I f the washer pump operates, but no
washer fl ui d i s emi tted from the washer nozzl es, be
certai n to check the fl ui d l evel i n the reservoi r. Check
for i ce or other forei gn materi al i n the reservoi r, and
for pi nched, di sconnected, broken, or i ncorrectl y
routed washer system pl umbi ng. For ci rcui t descri p-
ti ons and di agrams, refer to 8W-53 - Wi pers i n Group
INJURY.
Pl ace the rear wi per/washer swi tch i n the Wi pe posi -
ti on. Check whether the rear wi per i s operati ng. I f
OK, go to Step 2. I f not OK, see the Wi per System
di agnosi s i n thi s group.
Unpl ug the rear washer pump wi re harness connec-
tor. Measure the resi stance between the ground ci r-
cui t cavi ty of the rear washer pump wi re harness
i gni ti on swi tch to the On posi ti on. Depress the rear
washer swi tch. Measure the vol tage at the rear
washer motor control ci rcui t cavi ty of the rear
washer pump wi re harness connector. The meter
shoul d read battery vol tage. I f OK, repl ace the faul ty
pump. I f not OK, repai r the open ci rcui t as requi red.
FRONT
Perform the di agnosi s for the wi ndshi el d wi per sys-
tem and/or washer system as descri bed i n thi s group
before testi ng the mul ti -functi on swi tch. For ci rcui t
descri pti ons and di agrams, see 8W-53 - Wi pers i n
INJURY.
cabl e.
connector as descri bed i n thi s group.
(3) Usi ng an ohmmeter, perform the swi tch conti -
nui ty checks at the swi tch termi nal s as shown i n the
Mul ti -Functi on Swi tch Conti nui ty chart (Fi g. 2).
the wi per system and/or washer system wi re harness
ci rcui ts as requi red.
REAR
Perform the di agnosi s for the rear wi per system
and/or washer system as descri bed i n thi s group
before testi ng the rear wi per and washer swi tch. For
ci rcui t descri pti ons and di agrams, see 8W-53 - Wi p-
ers i n Group 8W - Wi ri ng Di agrams.
INJURY.
(1) Remove the rear wi per and washer swi tch as
(2) Usi ng an ohmmeter, check the swi tch conti nu-
i ty at the swi tch termi nal s as fol l ows:
a. Wi th the swi tch i n the Off posi ti on, there shoul d
be no conti nui ty between any two swi tch termi nal s.
b. Wi th the swi tch knob depressed i n the Wash
posi ti on, there shoul d be conti nui ty between the
fused i gni ti on swi tch output ci rcui t and the rear
washer motor control ci rcui t termi nal s.
c. Wi th the swi tch i n the I ntermi ttent posi ti on,
there shoul d be conti nui ty between the fused i gni ti on
swi tch output ci rcui t and the rear wi per motor con-
trol (i ntermi ttent) ci rcui t termi nal s.
d. Wi th the swi tch i n the On posi ti on, there shoul d
be conti nui ty between the fused i gni ti on swi tch out-
put ci rcui t and the rear wi per motor control ci rcui t
termi nal s.
the rear wi per system and/or washer system wi re
harness ci rcui ts as requi red.
8W-53 - Wi pers i n Group 8W - Wi ri ng Di agrams.
INJURY.
RELAY TEST
The i ntermi ttent wi pe 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 i ntermi ttent wi pe
rel ay i denti fi cati on and l ocati on.
Remove the i ntermi ttent wi pe rel ay from the PDC
as descri bed i n thi s group to perform the fol l owi ng
tests:
RELAY CIRCUIT TEST
connected to the wi per (mul ti -functi on) swi tch. There
shoul d be conti nui ty between the cavi ty for rel ay ter-
mi nal 30 and the two fused i gni ti on swi tch output
(V6) ci rcui t cavi ti es of the mul ti -functi on swi tch con-
nector at al l ti mes. I f OK, go to Step 2. I f not OK,
repai r the open ci rcui t(s) to the mul ti -functi on swi tch
as requi red.
connected to termi nal 30 i n the de-energi zed posi ti on.
There shoul d be conti nui ty between the cavi ty for
rel ay termi nal 87A and the wi per park swi tch sense
ci rcui t cavi ti es of the wi per motor wi re harness con-
nector and the whi te 24-way Body Control Modul e
Fig. 2 Multi-Function Switch Continuity
MULTIFUNCTION SWITCH PINS
Intermittent Wipe Relay
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
(BCM) wi re harness connector at al l ti mes. I f OK, go
to Step 3. I f not OK, repai r the open ci rcui t(s) to the
wi per motor and BCM as requi red.
gi zed posi ti on. There shoul d be battery vol tage at the
cavi ty for rel ay termi nal 87 wi th the i gni ti on swi tch
i n the On or Accessory posi ti ons. I f OK, go to Step 4.
I f not OK, repai r the open ci rcui t to the i gni ti on
swi tch as requi red.
the el ectromagnet i n the rel ay. There shoul d be bat-
tery 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 or Accessory posi ti ons.
to the i gni ti on swi tch as requi red.
the el ectromagnet i n the rel ay. I t i s grounded by the
BCM to energi ze the rel ay and cycl e the wi per motor.
Check for conti nui ty between the cavi ty for rel ay ter-
mi nal 85 and the i ntermi ttent wi per rel ay control ci r-
connector. There shoul d be conti nui ty. I f OK, refer to
di agnosi s of the BCM. I f not OK, repai r the open ci r-
cui t to the BCM as requi red.
WIPER BLADE AND ELEMENT
FRONT
NOTE: The pinch-release retainer end of the wiper
element should always be oriented towards the end
of the wiper blade that is nearest to the wiper pivot.
To remove the wi ndshi el d wi per bl ade and/or el e-
ment, proceed as fol l ows:
(1) Turn the wi ndshi el d wi per swi tch to the On
posi ti on. By turni ng the i gni ti on swi tch to the On
and Off posi ti ons, cycl e the wi per bl ades to a conve-
ni ent worki ng l ocati on on the wi ndshi el d.
(2) Li ft the wi per arm to rai se the wi per bl ade and
el ement off of the wi ndshi el d gl ass.
(3) Remove the wi per bl ade from the wi per arm, or
the wi per el ement from the wi per bl ade as fol l ows:
(a) To remove the wi per bl ade from the wi per
arm, push the rel ease tab under the arm ti p and
sl i de the bl ade away from the ti p towards the pi vot
end of the arm (Fi g. 3).
(b) To remove the wi per el ement from the wi per
bl ade, pi nch the notched retai ner (pi vot) end of the
wi per el ement ti ghtl y between the thumb and fore-
fi nger (Fi g. 4). Then, pul l the el ement fi rml y
towards the wi per pi vot to rel ease the wi per bl ade
cl aws from the wi per el ement retai ni ng pockets.
Once the cl aws are rel eased from the retai ni ng
pockets, the el ement wi l l sl i de easi l y out of the
remai ni ng cl aws.
(4) I nstal l the wi per bl ade on the wi per arm, or
the wi per el ement i n the wi per bl ade as fol l ows:
(a) To i nstal l the wi per bl ade on the wi per arm,
sl i de the bl ade retai ner i nto the U-shaped forma-
ti on on the ti p of the wi per arm unti l the rel ease
tab snaps i nto i ts l ocked posi ti on. Be certai n that
the pi nch-rel ease for the wi per el ement i s ori ented
towards the end of the wi per bl ade that i s nearest
to the wi per pi vot.
(b) To i nstal l the wi per el ement i n the wi per
bl ade, be certai n that the metal el ement rai l s (ver-
tebra) are properl y seated i n the sl ots on ei ther
si de of the rubber el ement. Start at the wi per pi vot
end of the bl ade and sl i de the el ement through
each pai r of wi per bl ade cl aws. The el ement i s ful l y
i nstal l ed when the cl aws on the wi per pi vot end of
the bl ade are engaged i n the wi per el ement retai n-
i ng pockets.
REAR
NOTE: The pinch-release retainer end of the wiper
element should always be oriented towards the end
of the wiper blade that is nearest to the rear wiper
motor output shaft.
Fig. 3 Wiper Blade Remove/Install - Typical
RELEASE TAB
Fig. 4 Wiper Element Remove
CLAW TO GRASP AND PULL CHANNEL RUBBER ELEMENT
VERTABRA
To remove the rear wi per bl ade and/or el ement,
proceed as fol l ows:
(1) Li ft the rear wi per arm to rai se the wi per bl ade
and el ement off of the l i ftgate gl ass.
(2) Remove the wi per bl ade from the wi per arm, or
the wi per el ement from the wi per bl ade as fol l ows:
(a) To remove the wi per bl ade from the wi per
arm, push the rel ease tab under the arm ti p and
sl i de the bl ade away from the ti p towards the rear
wi per motor output shaft end of the arm (Fi g. 3).
(b) To remove the wi per el ement from the wi per
bl ade, pi nch the notched (pi vot) end rel ease cl i p of
the wi per el ement ti ghtl y between the thumb and
forefi nger. Then, pul l the el ement fi rml y towards
the rear wi per motor output shaft to rel ease the
wi per el ement pi nch-rel ease cl i p from the wi per
bl ade cl aws. Once the cl i p i s rel eased from the
cl aws, the el ement wi l l sl i de easi l y out of the
remai ni ng cl aws.
(3) I nstal l the wi per bl ade on the wi per arm, or
the wi per el ement i n the wi per bl ade as fol l ows:
(a) To i nstal l the wi per bl ade on the wi per arm,
sl i de the bl ade retai ner i nto the U-shaped forma-
ti on on the ti p of the wi per arm unti l the rel ease
tab snaps i nto i ts l ocked posi ti on. Be certai n that
the pi nch-rel ease cl i p for the wi per el ement i s ori -
ented towards the end of the wi per bl ade that i s
nearest to the rear wi per motor output shaft.
(b) To i nstal l the wi per el ement i n the wi per
bl ade, start at the rear wi per motor output shaft
end of the bl ade and sl i de the el ement through
each pai r of wi per bl ade cl aws. The el ement i s ful l y
i nstal l ed when the cl aws on the rear wi per motor
output shaft end of the bl ade are engaged i n the
wi per el ement retai ni ng cl i p notches.
WIPER ARM
FRONT
CAUTION: The use of a screwdriver or other prying
tool to remove a wiper arm may distort it. This dis-
tortion could allow the arm to come off of the pivot
shaft, regardless of how carefully it is installed.
(1) Open the hood of the vehi cl e.
(2) Li ft the wi per arm to permi t the l atch to be
pul l ed out to i ts hol di ng posi ti on, then rel ease the
arm (Fi g. 5). The arm wi l l remai n off the wi ndshi el d
wi th the l atch i n thi s posi ti on.
(3) Remove the arm from the pi vot usi ng a rocki ng
moti on.
(4) I nstal l the arm and bl ade wi th the wi per motor
i n the Park posi ti on. See the Wi per Arm I nstal l ati on
i l l ustrati on (Fi g. 6). Mount the arms on the pi vot
shafts so that the di stance from the l ower edge of the
wi per arm ti p to the upper edge of the l ower wi nd-
shi el d moul di ng i s:
25 to 52 mm (0.98 to 2.04 i nch) on the dri ver
si de
33 to 62 mm (1.29 to 2.44 i nch) on the passenger
si de.
(5) Li ft the wi per arm away from the wi ndshi el d
sl i ghtl y to rel i eve the spri ng tensi on on the l atch.
Push the l atch i nto the l ocked posi ti on and sl owl y
rel ease the arm unti l the wi per bl ade rests on the
wi ndshi el d.
(6) Operate the wi pers wi th the wi ndshi el d gl ass
wet, then turn the wi per swi tch to the Off posi ti on.
Check for the correct wi per arm posi ti oni ng and
readjust i f requi red.
REAR
(1) Remove the wi per arm assembl y by l i fti ng the
pi vot cover and removi ng the retai ni ng nut (Fi g. 7).
(2) Remove the arm from the motor output shaft
usi ng a rocki ng moti on.
(3) I nstal l the rear wi per arm wi th the wi per
motor i n the Park posi ti on. Pl ace the rear wi per
Fig. 5 Wiper Arm Remove/Install
LOCKING LATCH ARM
Fig. 6 Front Wiper Arm Installation
1
1
4 -2
3
4 1
1
4 -2
3
4
bl ade i n the I nstal l ati on posi ti on on the ramp (Fi g. 8)
and ti ghten the retai ni ng nut to 18 Nm (160 i n.
l bs.).
(4) Cl ose the pi vot cover and move the rear wi per
bl ade to the Park posi ti on on the ramp.
WIPER MOTOR
FRONT
cabl e.
(2) Remove the wi per arms as descri bed i n thi s
group.
(3) Remove the screws that secure the cowl pl e-
num cover/gri l l e panel to the cowl top panel .
(4) Li ft the cowl pl enum cover/gri l l e panel from the
vehi cl e far enough to access the wi ndshi el d washer
nozzl e pl umbi ng.
(5) Di sconnect the wi ndshi el d washer suppl y hose
from the tee fi tti ng.
(6) Remove the cowl pl enum cover/gri l l e panel
from the vehi cl e and set i t asi de.
(7) Remove the fi ve screws that secure the wi per
modul e to the cowl mounti ng bracket (Fi g. 9).
(8) Move the wi per modul e as requi red to access
the wi per motor wi re harness connector.
(9) Unpl ug the wi per motor wi re harness connector
from the wi per motor.
(10) Remove the wi per modul e from the cowl pl e-
num.
(11) Turn the wi per modul e over and remove the
nut that secures the wi per motor crank arm to the
motor output shaft.
wi per motor to the wi per modul e and remove the
motor.
Wi per motor screws - 5 to 7 Nm (44 to 62 i n.
l bs.)
Crank arm nut - 10 to 12 Nm (88 to 106 i n. l bs.)
Wi per modul e mounti ng screws - 8 Nm (72 i n.
l bs.).
REAR
cabl e.
(2) Remove the rear wi per arm as descri bed i n thi s
group.
(3) Remove the nut that secures the motor from
the outsi de of the l i ftgate (Fi g. 10).
(4) Remove the external bezel and gasket.
(5) Remove the l i ftgate i nner tri m panel .
(6) Unpl ug the rear wi per motor wi re harness con-
nector.
(7) Remove the screws that secure the wi per motor
to the i nsi de of the l i ftgate.
(8) Remove the rear wi per motor.
Fig. 7 Rear Wiper Arm Remove/Install
PIVOT COVER WIPER ARM RETAINING NUT
Fig. 8 Rear Wiper Arm Installation
RAMP PARK POSITION INSTALLATION POSI- TION REAR WIPER BLADE
Fig. 9 Wiper Linkage Module Remove/Install
FWD WIPER BLADE WIPER ARM SCREWS (6) COWL GRILLE WIPER LINKAGE WASHER HOSE BOLTS (5) FENDER
Motor mounti ng screws - 1 to 1.7 Nm (10 to 15
i n. l bs.)
Motor mounti ng nut - 4 to 5.6 Nm (35 to 50 i n.
l bs.).
WIPER LINKAGE AND PIVOT
The wi per l i nkage and pi vots can onl y be removed
from or i nstal l ed i n the vehi cl e as a uni t wi th the
wi per motor. See Wi per Motor i n thi s group for the
cabl e.
(3) Refer to the l abel on the PDC for i ntermi ttent
wi pe rel ay i denti fi cati on and l ocati on.
(4) Unpl ug the i ntermi ttent wi pe rel ay from the
PDC.
(5) I nstal l the i ntermi ttent wi pe rel ay by al i gni ng
the rel ay termi nal s wi th the cavi ti es i n the PDC and
Fig. 10 Rear Wiper Motor Remove/Install
REAR WIPER BLADE NUT NUTGASKET NUT MOTOR SCREW NUT BEZEL
NEGATIVE CABLE
FRONT
INJURY.
cabl e.
(2) I f the vehi cl e i s so equi pped, remove the ti l t
steeri ng col umn l ever.
bezel s.
panel (Fi g. 12).
panel .
fl at-bl aded tool , gentl y pry the edges of the knee
bl ocker away from the i nstrument panel at the snap
cl i p retai ner l ocati ons (Fi g. 12).
from the vehi cl e.
(9) Remove both the upper and l ower shrouds from
(11) Loosen the steeri ng col umn upper bracket
nuts. Do not remove the nuts.
(12) Move the upper fi xed col umn shroud to gai n
access to the rear of the mul ti -functi on swi tch (Fi g.
14).
(13) Remove the mul ti -functi on swi tch tamper
proof mounti ng screws (a Snap On tamper proof torx
bi t TTXR20B2 or equi val ent i s requi red).
(14) Gentl y pul l the swi tch away from the col umn.
Loosen the wi re harness connector screw. The screw
wi l l remai n i n the wi re harness connector.
Typical
Fig. 14 Multi-Function Switch Connector -Typical
STEERING COL- UMN ASSY. MULTI-FUNCTION SWITCH CONNEC- TOR TURN SIGNAL SWITCH AND LEVER
mul ti -functi on swi tch.
Ti ghten the fasteners as fol l ows:
Mul ti -functi on swi tch wi re harness connector
screw - 2 Nm (17 i n. l bs.)
Mul ti -functi on swi tch retai ni ng screws - 2 Nm
(17 i n. l bs.)
Steeri ng col umn upper bracket nuts - 12 Nm
(110 i n. l bs.).
REAR
INJURY.
cabl e.
i nboard swi tch pod bezel and remove the bezel .
ness connectors.
i nstrument panel .
WASHER PUMP AND RESERVOIR
cabl e.
washer reservoi r to the i nner fender shi el d (Fi g. 16).
(3) Li ft the reservoi r far enough to access the
washer pump wi re harness connectors and hoses.
(4) Remove the washer hoses from the washer
pumps and drai n the washer fl ui d from the reservoi r
i nto a cl ean contai ner for reuse.
(5) Unpl ug the wi re harness connectors from the
washer pumps and the washer fl ui d l evel sensor, i f
the vehi cl e i s so equi pped.
(6) Use a deep socket and extensi on i nserted
through the reservoi r fi l l er neck to remove the
washer pump fi l ter/nuts from the i nsi de of the reser-
voi r.
(7) Remove the washer pumps from the reservoi r.
(8) I f the vehi cl e i s so equi pped, gentl y pry the
washer fl ui d l evel sensor away from the reservoi r.
Care must be taken not to damage the reservoi r.
(9) Remove the rubber grommet seal s from the
reservoi r and di scard.
Al ways use new rubber grommet seal s on the
reservoi r.
Fig. 16 Washer Reservoir Remove/Install
FENDER WASHER RESER- VOIR RESERVOIR MOUNTING BOLT WINDSHIELD WASHER PUMP LIFTGATE WASHER PUMP RESERVOIR MOUNTING BOLT
LAMPS
CONTENTS
page page
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . 19
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 7
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . 10
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 1
LAMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 13
LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 17
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 1
DAYTIME RUNNING LAMP DIAGNOSIS . . . . . . . 4
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 1
FOG LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . 3
HEADLAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . 2
LAMP OUTAGE MODULE DIAGNOSIS . . . . . . . . 5
GENERAL INFORMATION
GENERAL INFORMATION
Each vehi cl e i s equi pped wi th vari ous l amp assem-
bl i es. A good ground i s necessary for proper l i ghti ng
operati on. Groundi ng i s provi ded by the l amp socket
when i t comes i n contact wi th the metal body, or
through a separate ground wi re.
When changi ng l amp bul bs check the socket for
corrosi on. I f corrosi on i s present, cl ean i t wi th a wi re
brush and coat the i nsi de of the socket l i ghtl y wi th
Mopar Mul ti -Purpose Grease or equi val ent.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
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 are not hol di ng the com-
ponent i n pl ace.
DIAGNOSTIC PROCEDURES
When a vehi cl e experi ences probl ems wi th the
headl amp system, veri fy the condi ti on of the battery
connecti ons, chargi ng system, headl amp bul bs, wi re
connectors, rel ay, hi gh beam di mmer swi tch and
headl amp swi tch. Refer to Group 8W, Wi ri ng Di a-
grams for component l ocati ons and ci rcui t i nforma-
ti on.
ZG LAMPS 8L - 1
HEADLAMP DIAGNOSIS
HEADLAMP DIAGNOSIS
HEADLAMPS ARE DIM
WITH ENGINE IDLING
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
OR IGNITION TURNED
OFF
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge
, refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS BURN
OUT
1. Charging system output too high. 1. Test and repair charging system, refer to
Group 8A.
FREQUENTLY 2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
1. Charging system output too low. 1. Test and repair charging system, refer to
Group 8A.
ABOVE IDLE 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH
RANDOMLY
1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
2. High resistance in headlamp
circuit.
2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.
3. Faulty headlamps switch circuit
breaker.
3. Replace headlamp switch.
4. Loose or corroded terminals or
splices in circuit.
4. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS DO NOT
ILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer
(multi-function) switch.
4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.
5. Repair connector terminal or wire splice.
8L - 2 LAMPS ZG
FOG LAMP DIAGNOSIS
FOG LAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.
1. Loose or corroded
battery cables.
1. Clean and secure battery cable clamps and posts.
2. Loose or worn
generator drive belt.
2. Adjust or replace generator drive belt.
3. Charging system output
too low.
3. Test and repair charging system, refer to Group 8A.
4. Battery has insufficient
charge.
4. Test battery state-of-charge, refer to Group 8A.
5. Battery is sulfated or
shorted.
5. Load test battery, refer to Group 8A.
6. Poor lighting circuit
Z1-ground.
6. Test for voltage drop across Z1-ground locations,
refer to Group 8W.
7. Both fog lamp bulbs
defective.
7. Replace both lamp bulbs.
FOG LAMP BULBS BURN
OUT FREQUENTLY.
too high.
terminals or splices in
circuit.
2. Inspect and repair all connectors and splices, refer to
Group 8W.
FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE.
too low.
2. Poor fog lamp circuit
ground.
2. Test voltage drop across Z-1 ground, refer to Group
8W.
3. High resistance in fog
lamp circuit.
3. Test amperage draw of fog lamp circuit.
4. Both fog lamp bulbs
defective.
4. Replace both fog lamp bulbs.
FOG LAMPS FLASH
RANDOMLY.
1. Poor fog lamp circuit
ground.
1. Repair circuit ground, refer to Group 8W.
2. High resistance in fog
lamp circuit.
2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch
circuit breaker.
3. Replace fog lamp switch.
terminals or splices in
circuit.
4. Repair connector terminals or splices, refer to Group
8W.
FOG LAMPS DO NOT
ILLUMINATE.
1. Blown fuse for fog
lamps.
1. Replace fuse, refer to Group 8W.
2. No ground at fog
lamps.
2. Repair circuit ground, refer to Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector
terminal or wire splice in
fog lamp circuit.
4. Repair connector terminal or wire splices.
ZG LAMPS 8L - 3
DAYTIME RUNNING LAMP DIAGNOSIS
DAYTIME RUNNING LAMP DIAGNOSIS
DAYTIME RUNNING LAMPS DO
NOT WORK
1. Poor connection at DRL module.
2. Parking brake engaged.
3. Parking brake circuit shorted to
ground.
4. Headlamp circuit shorted to
ground.
5. Defective DRL module.
1. Secure connector on DRL
module.
2. Disengage parking brake.
3. Check voltage on pin 3 of
module, refer to Group 8W.
4. Check L3 circuit, refer to Group
8W.
5. Replace DRL module.
8L - 4 LAMPS ZG
LAMP OUTAGE MODULE DIAGNOSIS
LAMP OUTAGE MODULE DIAGNOSIS
LAMP FAILURE MESSAGE DISPLAYED ON VIC? YES RESET VIC BY CYCLING IGNITION SWITCH ON-OFF- ON. DONE ARE THE TAIL/STOP AND CHMSL LAMPS FUNC- TIONAL? NO YES DO TAIL/STOP AND CHMSL LAMPS HAVE CORRECT BULBS? REFER TO BULB APPLICATION CHART. NO
REPLACE ALL FAULTY OR INCORRECT BULBS. REFER TO BULB APPLICATION CHART.
ZG LAMPS 8L - 5
NOTE: The Lamp Outage Module contains an inter-
nal circuit breaker. When the module senses an
overload it will trip the circuit breaker and illumi-
nate a failure in the Vehicle Information Center
(VIC). The circuit breaker will reset once the vehicle
is turned off for approximately 60 seconds. Contin-
uous tripping of the circuit breaker may indicate a
circuit problem.
8L - 6 LAMPS ZG
HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
SERVICE PROCEDURES
FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . . . 9
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HEADLAMP ALIGNMENT PREPARATION . . . . . . 7
SPECIAL TOOLS
SPECIAL TOOLSHEADLAMP ALIGNMENT . . . 9
GENERAL INFORMATION
HEADLAMP ALIGNMENT
Headl amps can be al i gned usi ng the screen method
provi ded i n thi s secti on. Al i gnment Tool C-4466-A or
equi val ent can al so be used. Refer to i nstructi ons
provi ded wi th the tool for proper procedures. The
preferred headlamp alignment setting is 0 for
the left/right adjustment and 1 down for the
up/down adjustment.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) Correct defecti ve components that coul d hi nder
proper headl amp al i gnment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean headl amp l enses.
(5) Veri fy that l uggage area i s not heavi l y l oaded.
Fig. 1 Headlamp Alignment ScreenTypical
VEHICLE CENTERLINE CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS LEFT EDGE OF HIGH INTENSITY ZONE TOP EDGE OF HIGH INTENSITY ZONE FLOOR TO CENTER OF HEADLAMP LENS 7.62 METERS (25 FEET) FRONT OF HEADLAMP
ZG LAMPS 8L - 7
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 7.62 meters (25 ft) away from front
of headl amp l ens (Fi g. 1).
(2) I f necessary, tape a l i ne on the fl oor 7.62
meters (25 ft) away from and paral l el to the wal l .
(3) Measure from the fl oor up 1.27 meters (5 ft)
and tape a l i ne on the wal l at the centerl i ne of the
vehi cl e. Si ght al ong the centerl i ne of the vehi cl e
(from rear of vehi cl e forward) to veri fy accuracy of
the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for
up/down adjustment reference.
(7) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
A properl y ai med l ow beam wi l l project the top
edge of hi gh i ntensi ty pattern on the screen from 50
mm (2 i n.) above to 50 mm (2 i n.) bel ow headl amp
centerl i ne. The si de-to-si de l eft edge of hi gh i ntensi ty
pattern shoul d be from 50 mm (2 i n.) l eft to 50 mm
(2 i n.) ri ght of headl amp centerl i ne (Fi g. 1). The pre-
ferred headlamp alignment is 0 for the left/
right adjustment and 1 down for the up/down
adjustment. The hi gh beams on a vehi cl e wi th aero
headl amps cannot be al i gned. The hi gh beam pattern
shoul d be correct when the l ow beams are al i gned
properl y.
To adjust headl amp ai m, rotate al i gnment screws
(Fi g. 2).
Fig. 2 Aero Headlamp AlignmentScrews
IN/OUT ADJUSTER UP/DOWN ADJUSTER HEADLAMP
8L - 8 LAMPS ZG
FOG LAMP ADJUSTMENT
Prepare an al i gnment screen. A properl y al i gned
fog l amp wi l l project a pattern on the al i gnment
screen 100 mm (4 i n.) bel ow the fog l amp centerl i ne
and strai ght ahead (Fi g. 3).
Rotate the adjustment screw (Fi g. 4) to obtai n the
correct pattern.
SPECIAL TOOLS
SPECIAL TOOLS HEADLAMP ALIGNMENT
Fig. 3 Fog Lamp AlignmentTypical
VEHICLE CENTERLINE CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS HIGH-INTENSITY AREA FLOOR TO CENTER OF FOG LAMP LENS 100 mm (4 in.) 7.62 METERS (25 FEET) FRONT OF FOG LAMP
Fig. 4 Fog Lamp
ADJUSTMENT SCREW BRACKET CLIP BULB SOCKET ACCESS COVER FOG LAMP
Headlamp Aiming Kit C-4466A
ZG LAMPS 8L - 9
LAMP BULB SERVICE
INDEX
page page
CARGO LAMP BULB . . . . . . . . . . . . . . . . . . . . 12
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . 11
DOME LAMP BULB . . . . . . . . . . . . . . . . . . . . . 12
DOOR COURTESY LAMP BULB . . . . . . . . . . . 12
FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . 10
HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . 10
LICENSE PLATE LAMP BULB . . . . . . . . . . . . . . 11
OVERHEAD CONSOLE READING LAMP BULB . . 12
PARKING LAMP BULB . . . . . . . . . . . . . . . . . . . 11
READING LAMP BULB . . . . . . . . . . . . . . . . . . . 12
TAIL, STOP, TURN SIGNAL, BACK-UP AND
SIDE MARKER LAMP BULBS . . . . . . . . . . . . 11
TURN SIGNAL AND SIDE MARKER LAMP BULB . 11
UNDERHOOD LAMP BULB . . . . . . . . . . . . . . . 11
VISOR VANITY LAMP BULB . . . . . . . . . . . . . . . 12
HEADLAMP BULB
REMOVAL
(1) Li ft hood to access l amps.
I f cl earance i s mi ni mal behi nd the headl amp
assembl y, refer to the Headl amp Removal /I nstal l a-
ti on procedure for bul b repl acement.
(2) Reach i nto engi ne compartment and l ocate l ock
ri ng supporti ng the headl amp bul b assembl y.
(3) Rotate the l ock ri ng 1/8 turn countercl ockwi se
(Fi g. 1).
(4) Pul l the bul b strai ght out from the housi ng.
INSTALLATION
CAUTION: Do not touch the bulb glass with fin-
gers or other oily surfaces. Reduced bulb life will
result.
(1) I nstal l new bul b.
(2) Posi ti on bul b assembl y i n the l amp housi ng
and turni ng the l ock ri ng 1/8 turn cl ockwi se to
secure.
FOG LAMP BULB
REMOVE
(1) Remove the screws attachi ng the access cover
to the bottom of the fog l amp (Fi g. 2).
(2) Remove spri ng cl i p securi ng bul b to fog l amp.
(3) Di sconnect wi re connectors at bul b.
(4) Remove bul b el ement from fog l amp.
Fig. 1 Headlamp Bulb
LOCKRING BULB ASSEMBLY CONNECTOR
Fig. 2 Fog Lamp Bulb
8L - 10 LAMPS ZG
INSTALLATION
result.
(1) Posi ti on bul b el ement i n fog l amp.
(2) Connect wi re connectors at bul b.
(3) I nstal l spri ng cl i p securi ng bul b to fog l amp.
(4) I nstal l screws attachi ng the access cover to the
bottom of the fog l amp (Fi g. 2).
PARKING LAMP BULB
REMOVAL
(1) Remove l amp from vehi cl e
(2) Rotate socket countercl ockwi se and pul l socket
from l amp.
(3) Pul l bul b to from socket.
INSTALLATION
(1) Posi ti on bul b i n socket and push i nto pl ace.
(2) Posi ti on socket i n l amp and rotate socket cl ock-
wi se.
(3) I nstal l the l amp.
TURN SIGNAL AND SIDE MARKER LAMP BULB
REMOVAL
(1) Remove parki ng l amp.
(2) Remove turn si gnal /si de marker l amp.
(3) Rotate turn si gnal bul b socket countercl ock-
wi se, press i n on bul b and rotate 1/4 turn to remove.
(4) Rotate si demarker bul b socket countercl ock-
wi se grasp and pul l from l amp.
INSTALLATION
(1) I nstal l si de marker l amp bul b.
(2) I nstal l turn si gnal l amp bul b.
(3) I nstal l turn si gnal /si de marker l amp.
(4) I nstal l parki ng l amp.
TAIL, STOP, TURN SIGNAL, BACK-UP AND SIDE
MARKER LAMP BULBS
The stop, turn si gnal , back-up and rear si de
marker l amp bul bs are i ncorporated i nto the tai l
l amp.
REMOVAL
(1) Remove tai l l amp.
(2) Grasp bul b socket and rotate countercl ockwi se.
Separate socket from l amp.
(3) Pul l bul b from socket (Fi g. 3).
INSTALLATION
(2) Posi ti on bul b socket i n l amp and rotate cl ock-
wi se.
(3) I nstal l l amp.
LICENSE PLATE LAMP BULB
REMOVAL
(1) Remove screws attachi ng l i cense pl ate l amp to
l i cense pl ate housi ng.
(2) Separate l amp from housi ng.
(3) Grasp bul b and pul l from bul b socket.
INSTALLATION
(1) Posi ti on bul b i n socket and press i nto pl ace.
(2) Posi ti on l i cense pl ate l amp i n l i cense pl ate
housi ng.
(3) I nstal l screws attachi ng l i cense pl ate l amp to
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
BULB
REMOVAL
(1) Remove CHMSL from l i ftgate.
(2) Turn bul b socket 1/4 turn countercl ockwi se.
(3) Separate socket from l amp.
(4) Grasp bul b and pul l from socket.
INSTALLATION
(2) Posi ti on socket i n l amp.
(3) Turn bul b socket 1/4 turn cl ockwi se.
(4) I nstal l CHMSL.
UNDERHOOD LAMP BULB
REMOVAL
(1) Di sconnect the wi re harness connector from the
underhood l amp.
(2) Rotate the bul b countercl ock-wi se. Remove i t
from the l amp socket.
Fig. 3 Tail Lamp Bulbs
TAIL LAMP
TAIL/STOP BULB SOCKET
BACK-UP BULB SOCKET
ZG LAMPS 8L - 11
INSTALLATION
(1) I nsert the repl acement bul b i n the l amp base
socket. Rotate i t cl ockwi se.
(2) Connect the wi re harness connector to the
l amp.
VISOR VANITY LAMP BULB
REMOVAL
(1) Usi ng a smal l fl at bl ade, careful l y pry each cor-
ner of l ens outward from l amp.
(2) Separate l ens from l amp.
(3) Grasp bul b and pul l outward.
INSTALLATION
(2) Posi ti on l ens on l amp and snap i nto pl ace.
OVERHEAD CONSOLE READING LAMP BULB
REMOVAL
(1) I nsert a fl at bl ade screwdri ver i n sl ot at front
of l ens (Fi g. 4).
(2) Rotate the screwdri ver unti l l ens snaps out of
the housi ng.
(3) Remove l ens from housi ng.
(4) Remove bul b from termi nal s.
INSTALLATION
(1) I nsert bul b i nto readi ng l amp termi nal s.
(2) Repl ace l ens by hol di ng l ens l evel and pushi ng
rearward i nto housi ng.
(3) Push l ens up to snap i nto housi ng.
DOME LAMP BULB
REMOVAL
of l ens.
the housi ng.
(4) Remove bul b from socket.
INSTALLATION
READING LAMP BULB
REMOVAL
of l ens.
the housi ng.
(4) Remove bul b from termi nal s.
INSTALLATION
DOOR COURTESY LAMP BULB
REMOVAL
(1) Remove door tri m panel . Refer to Group 23,
Body Components for servi ce procedure.
(2) Remove bul b socket from l amp.
(3) Pul l bul b from socket.
INSTALLATION
(2) I nstal l bul b socket i n l amp.
(3) I nstal l door tri m panel .
CARGO LAMP BULB
REMOVAL
(1) I nsert a fl at bl ade screwdri ver i n sl ots provi ded
at l ower porti on of l ens.
(2) Rotate screwdri ver upward unti l l ens snaps out
of housi ng.
(4) Remove bul b from bul b socket.
INSTALLATION
(2) I nsert upper tabs of l ens i nto l ens housi ng.
(3) Snap l ower porti on of l ens i nto sl ots at l ens
housi ng.
Fig. 4 Overhead Console Reading Lamp Bulb
LENS FLAT BLADE CONSOLE
8L - 12 LAMPS ZG
LAMP SERVICE
INDEX
page page
CARGO LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 16
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DOME/READING LAMP . . . . . . . . . . . . . . . . . . 15
DOOR COURTESY LAMP . . . . . . . . . . . . . . . . 16
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . 14
PARKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . 13
TAIL, STOP, TURN SIGNAL, BACK-UP AND
SIDE MARKER LAMP . . . . . . . . . . . . . . . . . . 14
TURN SIGNAL AND SIDE MARKER LAMP . . . . 13
UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . 15
VISOR VANITY LAMP . . . . . . . . . . . . . . . . . . . . 15
HEADLAMP
REMOVAL
(1) Grasp l ower edge of headl amp l ens and pul l
strai ght back (away) from gri l l e openi ng rei nforce-
ment (GOR). Di sengage l ower adjuster pi vots from
l ens assembl y.
(2) Grasp upper edge of headl amp l ens. Pul l
strai ght back (away) from gri l l e openi ng rei nforce-
ment (GOR). Di sengage upper adjuster pi vot from
l ens assembl y.
(3) Rotate bul b l ock ri ng countercl ockwi se. and
remove ri ng and bul b from l ens.
INSTALLATION
(1) Repl ace by seati ng the assembl y i n the l amp
housi ng and turni ng the l ock ri ng 1/8 turn cl ockwi se
to secure.
(2) Al i gn upper adjust pi vot i nto headl amp open-
i ng and snap i nto pl ace.
(3) Snap l ower adjuster pi vots i nto pl ace.
FOG LAMP
REMOVAL
(1) Remove adjustment screw (Fi g. 1).
(2) Di sengage fog l amp el ectri cal connector.
(3) Separate fog l amp from vehi cl e.
INSTALLATION
(1) Posi ti on fog l amp at vehi cl e.
(2) Engage fog l amp el ectri cal connector.
(3) I nstal l adjustment screw (Fi g. 1).
(4) Al i gn fog l amp.
PARKING LAMP
REMOVAL
The parki ng l amp i s mounted on the si de of the
GOR next to headl amp assembl y.
(1) Open hood.
(2) Remove screws whi ch hol d the parki ng l amp i n
posi ti on (Fi g. 2).
(3) Rotate l amp socket countercl ockwi se and pul l
socket from l amp.
INSTALLATION
(1) Posi ti on l amp socket i n l amp and rotate cl ock-
wi se.
(2) Posi ti on l amp i n pl ace and i nstal l the screws.
TURN SIGNAL AND SIDE MARKER LAMP
REMOVAL
(1) Remove parki ng l amp.
(2) Remove the screws and sl i de l amp outboard to
expose the socket (Fi g. 3).
(3) Remove turn si gnal socket from l amp.
Fig. 1 Fog Lamp
ZG LAMPS 8L - 13
(4) Remove si demarker socket from l amp.
(5) Separate l amp from vehi cl e.
INSTALLATION
(1) I nstal l turn si gnal l amp socket.
(2) I nstal l si de marker l amp socket.
(3) Sl i de l amp i nto sl ot provi ded on i nboard si de of
headl amp assembl y.
(4) I nstal l screws.
(5) I nstal l parki ng l amp.
TAIL, STOP, TURN SIGNAL, BACK-UP AND SIDE
MARKER LAMP
The stop, turn si gnal , back-up and rear si de
marker l amps are i ncorporated i nto the tai l l amp.
REMOVAL
(1) Remove screws attachi ng l amp to body (Fi g. 4).
(2) Remove bul b sockets from l amp.
INSTALLATION
(1) Posi ti on l amp at vehi cl e and i nstal l bul b sock-
ets.
(2) Posi ti on l amp on vehi cl e and i nstal l screws.
LICENSE PLATE LAMP
REMOVAL
(1) Remove screws attachi ng l i cense pl ate l amp to
(2) Separate l amp from housi ng.
(3) Gri p bul b socket, rotate countercl ockwi se and
separate bul b socket from l i cense pl ate l amp.
INSTALLATION
(1) Posi ti on bul b socket i n l i cense pl ate l amp and
turn cl ockwi se.
(2) Posi ti on l i cense pl ate l amp i n l i cense pl ate
housi ng.
(3) I nstal l screws attachi ng l i cense pl ate l amp to
Fig. 2 Park Lamp
PARK LAMP MOUNTING SCREW TURN SIGNAL PARK LAMP HEADLAMP MOUNTING SCREW
Fig. 3 Turn Signal And SideMarker Lamp
SIDE MARKER BULB REMOVAL MOUNTING SLOT MOUNTING TAB TURN SIGNAL MOUNTINGSCREWS
Fig. 4 Tail Lamp
MOUNTING TABS RIGHT REAR LAMP
8L - 14 LAMPS ZG
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
REMOVAL
(1) Rai se l i ftgate.
(2) Remove upper l i ftgate tri m panel .
(3) Remove CHMSL l amp mounti ng screws (Fi g.
5).
(4) Remove CHMSL l amp.
(5) Turn bul b socket 1/4 turn countercl ockwi se.
(6) Separate socket from l amp.
INSTALLATION
(1) Posi ti on socket i n l amp.
(2) Turn bul b socket 1/4 turn cl ockwi se.
(3) Posi ti on CHMSL l amp i n pl ace and i nstal l
mounti ng screws.
(4) I nstal l upper l i ftgate tri m panel .
UNDERHOOD LAMP
REMOVAL
When equi pped, the underhood l amp i s i nstal l ed on
the hood ri ght, rear panel . The l amp i s on when hood
i s opened by way of l i qui d ON/OFF swi tch that i s
i ntegral wi th l amp base.
(1) Open hood.
(2) Remove screw attachi ng l amp support bracket
to hood (Fi g. 6).
(3) Di sengage connector for underhood l amp.
INSTALLATION
(1) Engage connector for underhood l amp.
(2) Posi ti on l amp on hood and i nstal l screw.
VISOR VANITY LAMP
REMOVAL
(1) Fol d down sunvi sor.
(2) Starti ng at the base of the l amp assembl y and
worki ng ri ght-to-l eft, use a smal l fl at bl ade, careful l y
pry l amp from vi sor.
(3) Di sconnect vi sor l amp wi re connector and
remove from vehi cl e.
INSTALLATION
(1) Posi ti on vi sor l amp at vi sor and connect vi sor
l amp wi re connector.
(2) Posi ti on vi sor l amp i n vi sor and press i nto
pl ace.
DOME/READING LAMP
REMOVAL
(1) I nsert a fl at bl ade screwdri ver i n sl ot at the
center of the l amp housi ng. Rotate screwdri ver
upward and unsnap dome l amp l ens.
(2) Pul l l ens downward. Remove i t from l amp
housi ng.
(3) Remove the l amp housi ng retai ni ng screws
(Fi g. 7).
(4) Push housi ng forward and rel ease housi ng
from bracket.
(5) Di sconnect wi re harness connectors.
(6) Remove l amp housi ng from headl i ner cavi ty.
INSTALLATION
(1) Posi ti on dome/readi ng l amp housi ng at head-
l i ner cavi ty.
(2) Connect wi re harness connectors.
(3) Locate rear pods of the l amp i n the sl ots of the
dome l amp bracket. Push l amp housi ng up and to
rear.
Fig. 5 Center High Mounted Stop Lamp
FWD LIFTGATE TRIM PANEL CHMSL
Fig. 6 Underhood Lamp
HOOD HOOD LAMP WIRING HOOD LAMP ASSEMBLY BULB
ZG LAMPS 8L - 15
(4) I nstal l the l amp housi ng screws.
(5) Posi ti on dome l amp l ens at l amp housi ng. Snap
l ens i nto housi ng.
DOOR COURTESY LAMP
REMOVAL
(1) Remove door tri m panel . Refer to Group 23,
Body Components for servi ce procedure.
(2) Remove bul b socket from l amp.
(3) Depress l amp l ocki ng tabs and separate l amp
from tri m panel .
INSTALLATION
(1) Posi ti on l amp i n tri m panel and snap i nto
pl ace.
(2) I nstal l bul b socket i n l amp.
CARGO LAMP
REMOVAL
(1) I nsert a fl at bl ade screwdri ver i n sl ots provi ded
at l ower porti on of l ens.
(2) Rotate screwdri ver upward unti l l ens snaps out
of housi ng.
(3) Remove l ens from housi ng (Fi g. 8).
(4) Remove screws attachi ng l i ftgate openi ng
upper tri m panel /cargo l amp to l i ftgate openi ng roof
panel .
(5) Separate tri m panel from roof panel .
(6) Di sengage el ectri cal connector for cargo l amp.
INSTALLATION
(1) Posi ti on tri m panel /cargo l amp at l i ftgate open-
i ng.
(2) Engage el ectri cal connector for cargo l amp.
(3) I nstal l screws attachi ng l i ftgate openi ng upper
tri m panel /cargo l amp to l i ftgate openi ng roof panel .
(4) Posi ti on l ens on cargo l amp and snap i nto
pl ace.
Fig. 7 Dome/Reading Lamp
DOME LAMP BRACKET DOME AND READING LAMPLENS
Fig. 8 Cargo Lamp
LIFTGATE OPENING UPPER PANEL CARGO LAMP LENS
8L - 16 LAMPS ZG
LAMP SYSTEMS
INDEX
page page
GENERAL INFORMATION
AUTO HEADLAMP SENSOR . . . . . . . . . . . . . . 17
DAYTIME RUNNING LAMP SYSTEM . . . . . . . . 17
LAMP OUTAGE MODULE . . . . . . . . . . . . . . . . . 17
AUTO HEADLAMP SENSOR . . . . . . . . . . . . . . 17
DAYTIME RUNNING LIGHT MODULE . . . . . . . 17
LAMP OUTAGE MODULE . . . . . . . . . . . . . . . . . 18
GENERAL INFORMATION
DAYTIME RUNNING LAMP SYSTEM
ZJ vehi cl es bui l t for use i n Canada are equi pped
wi th a Dayti me Runni ng Lamp System (DRL). The
DRL system operates the headl amp at 50% i l l umi na-
ti on wi th the headl amp swi tch OFF, park brake
rel eased and the i gni ti on i n the RUN posi ti on. The
DRL system i s control l ed by the Dayti me Runni ng
Lamp Modul e l ocated i n the engi ne compartment
attached to the Power Di stri buti on Center (PDC)
bracket. The DRL modul e overi des the headl amp
swi tch when the headl amps are turned OFF. The
headl amps operate normal l y when the headl amps are
turned ON.
LAMP OUTAGE MODULE
The Lamp Outage Modul e wi l l i ndi cate a tai l l amp,
stop l amp, or a CHMSL bul b fai l ure. A di spl ay wi l l
i l l umi nate i n the Vehi cl e I nformati on Center (VI C),
di spl ayi ng the fai l ure.
Detai l s for the VI C can be found i n Group 8E,
Vehi cl e I nformati on Center. For ci rcui t i nformati on,
refer to Group 8W, Wi ri ng Di agrams.
The Lamp Outage Modul e i s l ocated behi nd the l eft
quarter tri m panel .
Connecti ng trai l er l i ghts to the body harness at the
rear of the vehi cl e can cause damage to the l amp out-
age modul e. The l amp outage modul e i s desi gned to
handl e a 5 amp current l oad. Thi s i s adequate for the
operati on of the vehi cl es l i ghti ng system. When addi -
ti onal l i ghts are added to the system such as trai l er
l i ghts, the 5 amp l i mi t can be exceeded. Thi s can
cause fai l ure of the l amp outage modul e.
I f trai l er towi ng i s requi red and the vehi cl e i s not
equi pped wi th a trai l er tow package, the MOPAR
accessory trai l er towi ng harnesses are the onl y
approved method to provi de addi ti onal trai l er l i ghts.
These harnesses are desi gned to provi de current to
the trai l er l i ghts but bypass the l amp outage modul e.
AUTO HEADLAMP SENSOR
The auto headl amp sensor i s the key sensor for the
auto headl amp system. The sensor needs real sun-
l i ght to properl y regi ster the l i ght l evel . When auto
headl amps are enabl ed i ndoors, the headl amps may
be turned on. The sensor i s l ocated i n the center of
the defroster gri l l e at the base of the wi ndshi el d.
DAYTIME RUNNING LIGHT MODULE
REMOVAL
(1) Open hood.
(2) Di sconnect el ectri cal connector from modul e.
(3) Remove screws hol di ng modul e to PDC bracket
(Fi g. 1).
(4) Separate modul e from bracket.
INSTALLATION
(1) Reverse the removal procedures.
AUTO HEADLAMP SENSOR
REMOVAL
(1) Usi ng a tri m sti ck, gentl y pry defroster bezel
out of dash pad.
(2) Unpl ug auto headl amp sensor connector.
(3) Snap out sensor from bezel .
Fig. 1 Daytime Running Lamp Module
POWER DISTRIBUTION CENTER DAYTIME RUNNING LAMP MODULE BRACKET
ZG LAMPS 8L - 17
INSTALLATION
(1) Reverse the removal procedure.
LAMP OUTAGE MODULE
REMOVAL
(2) Remove spare ti re from carri er.
(3) Remove access door.
(4) Remove screw hol di ng modul e to i nner quarter
panel (Fi g. 2).
(5) Di sconnect wi ri ng connectors at modul e.
(6) Separate l amp outage modul e from vehi cl e.
INSTALLATION
(1) Connect wi ri ng connectors at modul e.
(2) I nstal l screw hol di ng modul e to i nner quarter
panel .
(3) I nstal l access door.
(4) I nstal l spare ti re.
Fig. 2 Lamp Outage Module
8L - 18 LAMPS ZG
BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 19
INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . 19
GENERAL INFORMATION
GENERAL INFORMATION
The fol l owi ng Bul b Appl i cati on Tabl es l i sts the
l amp ti tl e on the l eft si de of the col umn and trade
number or part number on the ri ght.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result. Do not
touch halogen bulbs with fingers or other oily sur-
faces. Bulb life will be reduced.
SPECIFICATIONS
EXTERIOR LAMPS
LAMP BULB
Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Center Hi gh Mounted Stopl amp . . . . . . . . . . . . . 922
Fog l amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3
Front Turn Si gnal . . . . . . . . . . . . . . . . . . . . 1295NA
Front Si de Marker . . . . . . . . . . . . . . . . . . . . . 194NA
Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Li cense Pl ate . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Tai l /Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Rear Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . . 3057
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . 105
INTERIOR LAMPS
Servi ce procedures for most of the l amps i n the
i nstrument panel , are l ocated i n Group 8E. Some
components have l amps that can onl y be servi ced by
an Authori zed Servi ce Center (ASC) after the compo-
nent i s removed from the vehi cl e. Contact l ocal
deal er for l ocati on of nearest ASC.
LAMP BULB
A/C Heater . . . . . . . . . . . . . . . . . . . . . . . . . 4720843
Ash Recei ver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Ci garette Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cl i mate Control . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Consol e Fl oor Shi fter . . . . . . . . . . . . . . . . . . . . . 194
Dome/Readi ng . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Door Courtesy . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Front Readi ng . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Gl ove Compartment . . . . . . . . . . . . . . . . . . . . . . 194
Hazard Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . . . . 212
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASC
Rear Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Rocker Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Shi ft Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Transfer Case Shi fter . . . . . . . . . . . . . . . . . . . . . 194
Theft Al arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Under Panel Courtesy . . . . . . . . . . . . . . . . . . . . . 89
ZG LAMPS 8L - 19
LAMPS
CONTENTS
page page
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . . 9
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . . 4
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 1
LAMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 2
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . 1
HEADLAMP MOTOR DIAGNOSIS . . . . . . . . . . . . 1
GENERAL INFORMATION
HEADLAMP LEVELING MOTOR
Thi s vehi cl e i s may be equi pped wi th a manual
headl amp l evel i ng system. Thi s system al l ows the
dri ver to adjust the headl amp beam hei ght depend-
i ng on passenger or cargo l oad. The headl amp beam
hei ght i s control l ed by a motor attached to each
headl amp and i s adjusted by a swi tch l ocated on the
consol e.
HEADLAMP MOTOR DIAGNOSIS
ONE MOTOR DOES NOT
OPERATE
1. Poor connection at motor.
2. No voltage at motor.
3. Defective motor.
1. Secure connector on motor.
2. Repair circuit.
3. Replace motor.
MOTORS DO NOT OPERATE 1. No voltage at switch.
2. No voltage at motors.
3. Poor connection at motors.
4. Both motors defective.
1. Repair circuit or replace fuse. Refer to
Group 8W.
2. Repair circuit or replace switch.
3. Secure connector on motors.
4. Replace motors.
ZG LAMPS 8L - 1
SERVICE PROCEDURES
INDEX
page
SERVICE PROCEDURES
SERVICE PROCEDURES
HEADLAMP ALIGNMENT
VEHICLE PREPARATION
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) I f equi pped wi th a motori zed headl amp l evel i ng
system, ensure the headl amp l evel i ng swi tch i s i n
the 0 posi ti on.
(3) Correct defecti ve components that coul d hi nder
proper headl amp al i gnment.
(4) Veri fy proper ti re i nfl ati on.
(5) Cl ean headl amp l enses.
(6) Veri fy that l uggage area i s not heavi l y l oaded.
(7) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 10 meters away from front of head-
l amp l ens (Fi g. 1).
(2) I f necessary, tape a l i ne on the fl oor 10 meters
away from and paral l el to the wal l .
(3) Measure from the fl oor up 1.27 meters (5 feet)
and tape a l i ne on the wal l at the centerl i ne of the
vehi cl e. Si ght al ong the centerl i ne of the vehi cl e
(from rear of vehi cl e forward) to veri fy accuracy of
the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
Fig. 1 Headlamp Alignment ScreenLeft Hand Drive
8L - 2 LAMPS ZG
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape).
(7) Pl ace a tape l i ne 150 mm bel ow and paral l el to
the center of headl amp l ens to the fl oor tape mark.
Use thi s for up/down al i gnment reference.
(8) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
HEADLAMP ADJ USTMENT
A properl y ai med l ow beam headl amp wi l l project
the top edge of hi gh i ntensi ty pattern on screen from
150 mm bel ow headl amp centerl i ne (Fi g. 1). The
angl e between the hori zontal and the i ncl i ned part of
the l i ght-dark boundary may not vary more than 10
cm to the ri ght or l eft of the verti cal through the cen-
ter mark.
To adjust headl amp ai m, rotate the headl amp
al i gnment screws to achi eve the pattern speci fi ed on
the al i gnment screen.
ZG LAMPS 8L - 3
LAMP BULB SERVICE
INDEX
page page
HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR FOG LAMP BULB . . . . . . . . . . . . . . . . . . . 5
SIDE REPEATER LAMP BULB . . . . . . . . . . . . . . 4
HEADLAMP BULB
REMOVAL
(1) Remove headl amp.
(2) Di sengage el ectri cal connector.
(3) Remove protecti ve boot from rear of headl amp
(Fi g. 1).
(4) Di sengage bul b retai ni ng cl i p (Fi g. 2).
(5) Pul l the bul b strai ght out from the housi ng.
INSTALLATION
result.
(1) Posi ti on bul b assembl y i n the l amp housi ng.
(2) Engage bul b retai ni ng cl i p.
(3) I nstal l protecti ve boot on rear of headl amp.
(4) Engage el ectri cal connector.
(5) I nstal l headl amp.
SIDE REPEATER LAMP BULB
REMOVAL
(1) I nsert a fl at bl ade or si mi l ar tool between l amp
and fender openi ng and pry the l amp away from the
fender (Fi g. 3). The retai ni ng tabs are l ocated at the
top and bottom of the l amp.
(2) Twi st l amp 1/4 turn cl ockwi se and pul l l amp
from socket (Fi g. 3).
(3) Twi st bul b 1/4 turn and pul l bul b from socket.
INSTALLATION
(1) Posi ti on bul b i n l amp socket and twi st bul b 1/4
turn.
(2) Push l amp on socket and turn 1/4 turn counter-
cl ockwi se.
(3) Push l amp i nto fender openi ng.
Fig. 1 Protective Boot
Fig. 2 Retaining Clip
Fig. 3 Repeater Lamp Lens
8L - 4 LAMPS ZG
REAR FOG LAMP BULB
REMOVAL
(1) Remove the tai l l amp.
(2) Grasp the fog l amp bul b socket and rotate
countercl ockwi se (Fi g. 4). Separate socket from l amp.
(3) Rotate bul b i n the socket countercl ockwi se and
remove bul b from socket.
INSTALLATION
(1) Posi ti on the bul b i n the socket and rotate cl ock-
wi se.
(2) Posi ti on the bul b socket i n the l amp and rotate
cl ockwi se.
(3) I nstal l the tai l l amp.
Fig. 4 Fog Lamp Bulb
ZG LAMPS 8L - 5
LAMP SERVICE
INDEX
page page
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR BUMPER REFLECTOR . . . . . . . . . . . . . . . 6
REAR FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . 6
SIDE REPEATER LAMP . . . . . . . . . . . . . . . . . . . 6
HEADLAMP
REMOVAL
(1) Remove the park l amp.
(2) Remove the metal cl i p retai ni ng the upper
pi vot of the headl amp to the headl amp l evel i ng
motor.
(3) Pul l the headl amp from the gri l l e openi ng rei n-
forcement (GOR).
(4) Di sengage the el ectri cal connector from the
rear of the headl amp
INSTALLATION
(1) Engage the el ectri cal connector on the rear of
the headl amp
(2) Posi ti on the headl amp i n the (GOR) and press
i nto pl ace.
(3) I nstal l the metal cl i p retai ni ng the upper pi vot
of the headl amp to the headl amp l evel i ng motor.
(4) I nstal l the park l amp.
SIDE REPEATER LAMP
REMOVAL
(1) I nsert a smal l fl at bl ade between l amp and
body panel . Di sengage l amp retai ni ng tabs (Fi g. 1).
(2) Twi st bul b socket 1/4 turn and separate bul b
socket from l amp (Fi g. 2).
INSTALLATION
(1) Posi ti on socket i n l amp and twi st socket 1/4
turn.
(2) Posi ti on l amp i nto body openi ng and push i nto
pl ace.
REAR FOG LAMP
The rear fog l amp i s i ntegrated i nto the rear tai l
l amp. Refer to the Rear Tai l Lamp Removal /I nstal l a-
ti on procedure.
REAR BUMPER REFLECTOR
REMOVAL
(1) From the undersi de of the vehi cl e, remove the
nut attachi ng the refl ector to the backsi de of the rear
bumper.
(2) Separate the refl ector from the rear bumper.
Fig. 1 Repeater Lamp Retaining Tabs
Fig. 2 Repeater Lamp
8L - 6 LAMPS ZG
INSTALLATION
(1) Posi ti on the refl ector on the rear bumper (Fi g.
3).
(2) I nstal l the nut attachi ng the refl ector to the
rear bumper.
Fig. 3 Rear Bumper Reflector
ZG LAMPS 8L - 7
LAMP SYSTEMS
INDEX
page
HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . 8
HEADLAMP LEVELING MOTOR
REMOVAL
(1) Remove headl amp.
(2) Remove screws attachi ng l evel i ng motor to
gri l l e openi ng rei nforcement (GOR) (Fi g. 1).
(3) Gentl y push l evel i ng motor downward and pul l
from GOR.
(4) Squeeze el ectri cal connector tabs i nward and
pul l connector from l evel i ng motor.
(5) Separate l evel i ng motor from vehi cl e.
INSTALLATION
(1) Engage el ectri cal connector to l evel i ng motor.
(2) Posi ti on l evel i ng motor i n GOR and i nstal l
screws.
(3) I nstal l headl amp.
Fig. 1 Headlamp Leveling Motor
8L - 8 LAMPS ZG
BULB APPLICATION
INDEX
page
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
EXTERIOR LAMPS
LAMP BULB
Front Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . H3
Front Turn Si gnal Lamp . . . . . . . . . . . . . . . . . P21W
Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4
Li cense Pl ate Lamp . . . . . . . . . . . . . . . . . . . . . W5W
Park Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . W3W
Park Lamp (Japan Onl y) . . . . . . . . . . . . . . . . . W3W
Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . P21W
Rear Turn Si gnal Lamp . . . . . . . . . . . . . . . . . P21W
Si de Repeater Lamp . . . . . . . . . . . . . . . . . . . . . T4W
Stop Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . P21/5W
Tai l Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . P21/5W
ZG LAMPS 8L - 9
PASSIVE RESTRAINT SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . 3
AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . 2
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . 3
IMPACT SENSOR . . . . . . . . . . . . . . . . . . . . . . . 3
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANUP PROCEDURE . . . . . . . . . . . . . . . . . . 4
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . 8
AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . 5
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . 9
DRIVER SIDE AIRBAG TRIM COVER AND
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 6
PASSENGER SIDE AIRBAG REAR MOUNTING
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ADJUSTMENTS
CLOCKSPRING CENTERING . . . . . . . . . . . . . . 10
GENERAL INFORMATION
INTRODUCTION
A dual front ai rbag system i s a standard equi p-
ment safety feature on thi s model . The system
i ncl udes an i nfl atabl e ai rbag modul e i n the center of
the steeri ng wheel , and a second i nfl atabl e ai rbag
modul e i n the i nstrument panel above the gl ove box.
Thi s system i s desi gned to reduce seri ous i njuri es to
the dri ver and front seat passenger duri ng a frontal
i mpact of the vehi cl e.
To test thi s passi ve restrai nt system, refer to the
proper Di agnosti c Procedures manual . I f an ai rbag
modul e assembl y i s defecti ve and non-depl oyed, refer
to the Chrysl er Corporati on current parts return l i st
i n the Warranty Pol i ci es and Procedures manual for
the proper handl i ng procedures.
components i n the ai rbag system. Refer to 8W-43 -
Ai rbag System i n Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams.
ZG PASSIVE RESTRAINT SYSTEMS 8M - 1
WARNING:
THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
INJURY.
THE AIRBAG MODULE INFLATOR ASSEMBLY
CONTAINS SODIUM AZIDE AND POTASSIUM
NITRATE. THESE MATERIALS ARE POISONOUS
AND EXTREMELY FLAMMABLE. CONTACT WITH
ACID, WATER, OR HEAVY METALS MAY PRODUCE
HARMFUL AND IRRITATING GASES (SODIUM
HYDROXIDE IS FORMED IN THE PRESENCE OF
MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN
ADDITION, THE PASSENGER AIRBAG MODULE
CONTAINS ARGON GAS PRESSURIZED TO OVER
2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN
AIRBAG MODULE OR TAMPER WITH ITS INFLA-
TOR. DO NOT PUNCTURE, INCINERATE, OR BRING
INTO CONTACT WITH ELECTRICITY. DO NOT
STORE AT TEMPERATURES EXCEEDING 93 C
(200 F).
REPLACE AIRBAG SYSTEM COMPONENTS
ONLY WITH PARTS SPECIFIED IN THE CHRYSLER
MOPAR PARTS CATALOG. SUBSTITUTE PARTS
MAY APPEAR INTERCHANGEABLE, BUT INTERNAL
DIFFERENCES MAY RESULT IN INFERIOR OCCU-
PANT PROTECTION.
THE FASTENERS, SCREWS, AND BOLTS
ORIGINALLY USED FOR THE AIRBAG SYSTEM
COMPONENTS HAVE SPECIAL COATINGS AND
ARE SPECIFICALLY DESIGNED FOR THE AIRBAG
SYSTEM. THEY MUST NEVER BE REPLACED WITH
ANY SUBSTITUTES. ANY TIME A NEW FASTENER
IS NEEDED, REPLACE IT WITH THE CORRECT FAS-
TENERS PROVIDED IN THE SERVICE PACKAGE OR
SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT-
ALOG.
WHEN A STEERING COLUMN HAS AN AIRBAG
MODULE ATTACHED, NEVER PLACE THE COLUMN
ON THE FLOOR OR ANY OTHER SURFACE WITH
THE STEERING WHEEL OR AIRBAG MODULE FACE
DOWN.
AIRBAG MODULE
DRIVER SIDE
The ai rbag modul e protecti ve tri m cover i s the
most vi si bl e part of the dri ver si de ai rbag system.
The modul e i s mounted di rectl y to the steeri ng
wheel . Located under the ai rbag modul e tri m cover
are the horn swi tch, the ai rbag cushi on, and the ai r-
bag cushi on supporti ng components. The ai rbag mod-
ul e i ncl udes a housi ng to whi ch the cushi on and
i nfl ator are attached and seal ed. The ai rbag modul e
cannot be repai red, and must be repl aced i f depl oyed
or i n any way damaged.
The i nfl ator assembl y i s mounted to the back of
the ai rbag modul e. The i nfl ator seal s the hol e i n the
ai rbag cushi on so i t can di scharge the gas i t produces
di rectl y i nto the cushi on when suppl i ed wi th the
proper el ectri cal si gnal . The protecti ve tri m cover i s
fi tted to the front of the ai rbag modul e and forms a
decorati ve cover i n the center of the steeri ng wheel .
Upon ai rbag depl oyment, thi s cover wi l l spl i t at a
predetermi ned breakout l i ne.
PASSENGER SIDE
The i nstrument panel top pad i s the most vi si bl e
part of the passenger si de ai rbag system. Located
under the i nstrument panel top pad are the ai rbag
cushi on and i ts supporti ng components. The ai rbag
modul e i ncl udes a housi ng to whi ch the cushi on and
i nfl ator are attached and seal ed. The ai rbag modul e
cannot be repai red, and must be repl aced i f depl oyed
or i n any way damaged.
The i nfl ator assembl y i s mounted to the back of
the ai rbag modul e. The i nfl ator seal s the hol e i n the
ai rbag cushi on so i t can di scharge the gas i t produces
di rectl y i nto the cushi on when suppl i ed wi th the
proper el ectri cal si gnal . The i nstrument panel top
pad above the gl ove box openi ng has a door and pre-
determi ned breakout l i nes conceal ed beneath i ts dec-
orati ve cover. Upon ai rbag depl oyment, the top pad
wi l l spl i t at the breakout l i nes and the door wi l l pi vot
out of the way.
The ai rbag modul e i s secured to two mounti ng
brackets beneath the i nstrument panel top pad and
above the gl ove box openi ng. The ai rbag front mount-
i ng bracket (cl osest to the dash panel ) i s wel ded to
the i nstrument panel armature. The ai rbag rear
mounti ng bracket (cl osest to the passenger) i s bol ted
to the i nstrument panel armature. Fol l owi ng an ai r-
bag depl oyment, the ai rbag rear mounti ng bracket
and the i nstrument panel top pad must be repl aced.
I f the ai rbag front mounti ng bracket i s damaged, the
i nstrument panel armature assembl y must al so be
repl aced.
8M - 2 PASSIVE RESTRAINT SYSTEMS ZG
STORAGE
An ai rbag modul e must be stored i n i ts ori gi nal ,
speci al contai ner unti l used for servi ce. Al so, i t must
be stored i n a cl ean, dry envi ronment; away from
sources of extreme heat, sparks, and hi gh el ectri cal
energy. Al ways pl ace or store an ai rbag modul e on a
surface wi th i ts tri m cover or ai rbag si de faci ng up,
to mi ni mi ze movement i n case of an acci dental
depl oyment.
IMPACT SENSOR
The i mpact sensor provi des veri fi cati on of the
di recti on and severi ty of an i mpact. One i mpact sen-
sor i s used. I t i s l ocated i nsi de the Ai rbag Control
Modul e (ACM), whi ch i s secured to a bracket on the
fl oor pan transmi ssi on tunnel i nsi de the vehi cl e.
The i mpact sensor i s an accel erometer that senses
the rate of decel erati on. The mi croprocessor i n the
ACM moni tors the i mpact sensor si gnal . A pre-pro-
grammed deci si on al gori thm i n the mi croprocessor
determi nes when the decel erati on rate i ndi cates an
i mpact that i s severe enough to requi re ai rbag sys-
tem protecti on. When the programmed condi ti ons are
met, the ACM sends an el ectri cal si gnal to depl oy the
ai rbag system components.
The i mpact sensor i s cal i brated for the speci fi c
vehi cl e. The sensor i s onl y servi ced as a uni t wi th the
ACM. The sensor cannot be repai red or adjusted and,
i f faul ty or damaged, the ACM uni t must be repl aced.
CLOCKSPRING
The cl ockspri ng i s mounted on the steeri ng col umn
behi nd the steeri ng wheel . Thi s assembl y consi sts of
a pl asti c housi ng whi ch contai ns a fl at, ri bbon-l i ke,
el ectri cal l y conducti ve tape that wi nds and unwi nds
wi th the steeri ng wheel rotati on.
The cl ockspri ng i s used to mai ntai n a conti nuous
el ectri cal ci rcui t between the wi re harness and the
dri ver si de ai rbag modul e, the horn swi tch, the vehi -
cl e speed control swi tches, and the remote radi o
swi tches on vehi cl es that are so equi pped. There are
al so separate versi ons of the cl ockspri ng for model s
equi pped wi th or wi thout the opti onal speed propor-
ti onal steeri ng. Refer to Group 19 - Steeri ng for more
i nformati on.
The cl ockspri ng must be properl y centered when i t
i s i nstal l ed on the steeri ng col umn fol l owi ng any ser-
vi ce removal , or i t wi l l be damaged. See the Cl ock-
spri ng Centeri ng procedure i n thi s group for more
i nformati on.
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the ai rbag has been
depl oyed, the cl ockspri ng must be repl aced.
AIRBAG CONTROL MODULE
The Ai rbag Control Modul e (ACM) contai ns the
i mpact sensor, and a mi croprocessor that moni tors
the i mpact sensor si gnal s and the ai rbag system el ec-
tri cal ci rcui ts to determi ne the system readi ness. The
ACM contai ns On-Board Di agnosti cs (OBD), and wi l l
send an ai rbag l amp-on message to the i nstrument
cl uster on the Chrysl er Col l i si on Detecti on (CCD)
data bus to l i ght the ai rbag i ndi cator l amp i n the
i nstrument cl uster when a moni tored ai rbag system
faul t occurs.
The ACM al so contai ns an energy-storage capaci -
tor. Thi s capaci tor stores enough el ectri cal energy to
depl oy the ai rbags for up to one second fol l owi ng a
battery di sconnect or fai l ure duri ng an i mpact. The
purpose of the capaci tor i s to provi de ai rbag system
protecti on i n a severe secondary i mpact, i f the i ni ti al
i mpact has damaged or di sconnected the battery, but
was not severe enough to depl oy the ai rbags.
The ACM cannot be repai red and, i f damaged or
AIRBAG SYSTEM
A DRB scan tool i s requi red for di agnosi s of the
ai rbag system. Refer to the proper Di agnosti c Proce-
dures manual for more i nformati on.
cabl e. I f the ai rbag has not been depl oyed, wai t two
mi nutes for the system capaci tor to di scharge before
further servi ce.
(2) Connect the DRB scan tool to the 16-way data
l i nk wi re harness connector. The connector i s l ocated
on the dri ver si de l ower edge of the i nstrument
panel , outboard of the steeri ng col umn (Fi g. 1).
Exi t the vehi cl e wi th the DRB. Use the l atest versi on
of the proper DRB cartri dge.
(4) After checki ng that nobody i s i nsi de the vehi -
cl e, reconnect the battery negati ve cabl e.
(5) Usi ng the DRB, read and record the acti ve
Di agnosti c Troubl e Code (DTC) data.
(6) Read and record any stored DTC data.
(7) Refer to the proper Di agnosti c Procedures man-
ual , i f any DTC i s found i n Step 5 or Step 6.
(8) Erase the stored DTC data. I f any probl ems
remai n, the stored DTC data wi l l not erase.
(9) Wi th the i gni ti on swi tch sti l l i n the On posi -
ti on, make sure nobody i s i n the vehi cl e.
(10) From outsi de of the vehi cl e (away from the
ai rbag modul es i n case of an acci dental depl oyment)
turn the i gni ti on swi tch to the Off posi ti on for about
ten seconds, and then back to the On posi ti on.
Observe the ai rbag i ndi cator l amp i n the i nstrument
cl uster. I t shoul d l i ght for si x to ei ght seconds, and
then go out. Thi s i ndi cates that the ai rbag system i s
functi oni ng normal l y.
NOTE: If the airbag indicator lamp fails to light, or
lights and stays on, there is an airbag system mal-
function. Refer to the proper Diagnostic Procedures
manual to diagnose the problem.
SERVICE PROCEDURES
AIRBAG SYSTEM
NON-DEPLOYED
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of an ai rbag
modul e. When carryi ng a non-depl oyed ai rbag mod-
ul e, the tri m cover or ai rbag si de of the modul e
shoul d be poi nted away from the body to mi ni mi ze
i njury i n the event of an acci dental depl oyment. I f
the modul e i s pl aced on a bench or any other surface,
the tri m cover or ai rbag si de of the modul e shoul d be
face up to mi ni mi ze movement i n the event of an
acci dental depl oyment.
I n addi ti on, the ai rbag system shoul d be di sarmed
whenever any steeri ng wheel , steeri ng col umn, or
i nstrument panel components requi re di agnosi s or
servi ce. Fai l ure to observe thi s warni ng coul d resul t
i n acci dental ai rbag depl oyment and possi bl e per-
sonal i njury. Refer to Group 8E - I nstrument Panel
Systems for addi ti onal servi ce procedures on the
i nstrument panel . Refer to Group 19 - Steeri ng for
addi ti onal servi ce procedures on the steeri ng wheel
and steeri ng col umn.
DEPLOYED
Any vehi cl e whi ch i s to be returned to use after an
ai rbag depl oyment, must have both ai rbag modul es,
the cl ockspri ng, the i nstrument panel top pad, and
the passenger si de ai rbag rear mounti ng bracket
repl aced. These components wi l l be damaged or
weakened as a resul t of an ai rbag depl oyment, whi ch
may or may not be obvi ous duri ng a vi sual i nspec-
ti on, and are not i ntended for reuse.
Other vehi cl e components shoul d be cl osel y
i nspected, but are to be repl aced onl y as requi red by
the extent of the vi si bl e damage i ncurred.
CLEANUP PROCEDURE
Fol l owi ng an ai rbag system depl oyment, the vehi -
cl e i nteri or wi l l contai n a powdery resi due. Thi s res-
i due i s pri mari l y sodi um bi carbonate (baki ng soda),
used as an ai rbag cushi on l ubri cant. However, there
wi l l al so be traces of sodi um hydroxi de powder, a
chemi cal by-product of the generant used for ai rbag
depl oyment. Si nce thi s powder can i rri tate the ski n,
eyes, nose, or throat, be sure to wear safety gl asses,
rubber gl oves, and a l ong-sl eeved shi rt duri ng
cl eanup (Fi g. 2).
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
IRRITATION OF THE NOSE OR THROAT, EXIT THE
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
CIAN.
Begi n the cl eanup by removi ng the ai rbag modul es
from the vehi cl e as descri bed i n thi s group.
Use a vacuum cl eaner to remove any resi dual pow-
der from the vehi cl e i nteri or. Cl ean from outsi de the
Fig. 1 16-Way Data Link Connector - Typical
16WAY DATA LINK CONNECTOR BOTTOM OF INSTRU- MENT PANEL
Fig. 2 Wear Safety Glasses and Rubber Gloves
vehi cl e and work your way i nsi de, so that you avoi d
kneel i ng or si tti ng on a non-cl eaned area.
Be sure to vacuum the heater and ai r condi ti oni ng
outl ets as wel l (Fi g. 3). Run the heater and ai r con-
di ti oni ng bl ower on the l owest speed setti ng and vac-
uum any powder expel l ed from the outl ets. You may
need to vacuum the i nteri or of the vehi cl e a second
ti me to recover al l of the powder.
Pl ace the depl oyed ai rbag modul es i n your vehi cu-
l ar scrap pi l e.
AIRBAG MODULE
WARNING:
INJURY.
WHEN REMOVING A DEPLOYED AIRBAG
MODULE, RUBBER GLOVES, EYE PROTECTION,
AND A LONG-SLEEVED SHIRT SHOULD BE WORN.
THERE MAY BE DEPOSITS ON THE AIRBAG MOD-
ULE AND OTHER INTERIOR SURFACES. IN LARGE
DOSES, THESE DEPOSITS MAY CAUSE IRRITATION
TO THE SKIN AND EYES.
DRIVER SIDE
cabl e. I f the ai rbag modul e has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) From the undersi de of the steeri ng wheel ,
remove the three screws that secure the dri ver si de
ai rbag modul e to the steeri ng wheel (Fi g. 4).
(3) Pul l the ai rbag modul e away from the steeri ng
wheel far enough to unpl ug the ai rbag modul e and
horn swi tch wi re harness connectors from the back of
the ai rbag modul e.
(4) Remove the ai rbag modul e from the steeri ng
wheel .
(5) I f the ai rbag has been depl oyed, see the proce-
dure for repl aci ng the cl ockspri ng i n thi s group.
(6) When i nstal l i ng the ai rbag modul e, connect the
cl ockspri ng wi re harness connector to the modul e by
pressi ng strai ght i n on the connector. Be certai n that
the connector i s ful l y engaged by observi ng the l atch-
i ng cl i p arms on the top of the connector.
(7) I nstal l the three ai rbag modul e mounti ng
screws and ti ghten to 10.2 Nm (90 i n. l bs.).
(8) Do not connect the battery negati ve cabl e at
thi s ti me. See Ai rbag System i n Di agnosi s and Test-
i ng for the proper procedures.
PASSENGER SIDE
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged passenger si de ai rbag modul e. I f
the passenger si de ai rbag modul e has been depl oyed,
the i nstrument panel top pad and passenger si de ai r-
bag rear mounti ng bracket must be repl aced. Refer to
Group 8E - I nstrument Panel Systems for the proce-
dures requi red for i nstrument panel top pad servi ce.
Fig. 3 Vacuum Heater and A/C Outlets
Fig. 4 Driver Side Airbag Module Remove/Install
DRIVERS AIRBAG MODULE AIRBAG WIRE HORN SWITCH WIRE SCREWS FWD
(2) Remove the i nstrument panel top pad. Refer to
dures.
(3) Remove the two screws that secure the ai rbag
modul e to the front ai rbag mounti ng bracket (Fi g. 5).
(4) Remove the two screws that secure the ai rbag
modul e to the rear ai rbag mounti ng bracket.
(5) Unpl ug the ai rbag modul e wi re harness con-
nector and remove the ai rbag modul e from the
i nstrument panel .
(6) I f the ai rbag has been depl oyed, see the proce-
dure for repl aci ng the passenger si de rear ai rbag
mounti ng bracket i n thi s group.
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
PASSENGER SIDE AIRBAG MODULE, OR BECOM-
ING ENTRAPPED BETWEEN THE INSTRUMENT
PANEL TOP PAD AND THE PASSENGER SIDE AIR-
BAG MODULE. FAILURE TO OBSERVE THIS WARN-
ING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(7) I nstal l and ti ghten the ai rbag modul e mount-
i ng screws to 11.75 Nm (105 i n. l bs.).
NOTE: If the airbag module mounting screws can-
not be tightened to the specified torque value,
replace the screws with the oversized screws spec-
ified in the Mopar Parts Catalog.
(9) When rei nstal l i ng the passenger si de ai rbag
modul e, be certai n that the ai rbag modul e wi re har-
ness connector l atches are ful l y engaged.
DRIVER SIDE AIRBAG TRIM COVER AND HORN
SWITCH
WARNING:
INJURY.
THE HORN SWITCH IS INTEGRAL TO THE AIR-
BAG MODULE TRIM COVER. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(2) Remove the dri ver si de ai rbag modul e as
(3) Remove the two pl asti c horn swi tch feed wi re
retai ners from the studs on the ai rbag housi ng (Fi g.
6).
(4) Unpl ug the horn swi tch ground wi re from the
ai rbag modul e l ower tri m cover retai ner.
(5) Remove the four nuts that secure the upper
and l ower tri m cover retai ners to the studs on the
ai rbag housi ng (Fi g. 7).
(6) Remove the upper and l ower tri m cover retai n-
ers from the ai rbag housi ng studs.
(7) Di sengage the fi ve tri m cover l ocki ng bl ocks
from the l i p around the outsi de edge of the ai rbag
housi ng and remove the housi ng from the cover (Fi g.
8).
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
DRIVER SIDE AIRBAG MODULE, OR BECOMING
ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG
MODULE TRIM COVER AND THE DRIVER SIDE AIR-
BAG MODULE. FAILURE TO OBSERVE THIS WARN-
ING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
Fig. 5 Passenger Side Airbag Module Remove/Install
PASSENGERS AIRBAG MODULE REAR MOUNTING BRACKET FRONT MOUNTING BRACKET WIRING TROUGH MOUNTING SCREWS
(8) When i nstal l i ng the tri m cover and horn
swi tch, be certai n that the l ocki ng bl ocks are ful l y
engaged on the l i p of the ai rbag housi ng (Fi g. 9).
(9) When i nstal l i ng the upper and l ower tri m cover
retai ners, be certai n that the tabs on each retai ner
are engaged i n the retai ner sl ots of the tri m cover
(Fi g. 8).
(10) I nstal l and ti ghten the tri m cover retai ner
nuts to 10 Nm (90 i n. l bs.).
compl ete the i nstal l ati on, but do not connect the bat-
tery negati ve cabl e at thi s ti me. See Ai rbag System
i n Di agnosi s and Testi ng for the proper procedures.
PASSENGER SIDE AIRBAG REAR MOUNTING
BRACKET
(1) Remove the passenger si de ai rbag modul e as
Fig. 6 Horn Switch Feed Wires Remove/Install
HORN SWITCH FEED WIRE HORN SWITCH GROUNDWIRE WIRE RETAINERS
Fig. 7 Airbag Trim Cover Retainers Remove/Install
INFLATOR UPPER RETAINER AIRBAG HOUSING STUDS NUT (4) LOWER RETAINER TRIM COVER
Fig. 8 Airbag Trim Cover Remove/Install
RETAINER SLOTS TRIM COVER LOCKING BLOCKS RETAINER SLOTS HORN SWITCH
Fig. 9 Airbag Trim Cover Locking BlocksInstalled
LIP TRIM COVER HORN SWITCH AIRBAG HOUSING LOCKING BLOCK
(2) Remove the screws that secure the i nstrument
panel wi re harness trough to the ai rbag rear mount-
i ng bracket.
(3) Remove the heater-A/C control from the i nstru-
ment panel . Refer to Group 24 - Heati ng and Ai r
Condi ti oni ng for the procedures.
(4) Reach through the heater-A/C control openi ng
i n the i nstrument panel to remove the two bol ts that
secure the i nboard end of the ai rbag rear mounti ng
bracket to the i nstrument panel armature (Fi g. 10).
(5) Remove the two bol ts that secure the outboard
end of the ai rbag rear mounti ng bracket from the
passenger si de outboard end of the i nstrument panel
armature (Fi g. 11).
(6) Remove the ai rbag rear mounti ng bracket
through the l ower openi ng of the i nstrument panel
armature, outboard end fi rst.
Ti ghten the mounti ng bol ts to 11.75 Nm (105 i n.
l bs.).
WARNING:
THE AIRBAG CONTROL MODULE CONTAINS
THE IMPACT SENSOR, WHICH ENABLES THE SYS-
TEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT-
ING TO DIAGNOSE OR SERVICE ANY AIRBAG
SYSTEM OR RELATED STEERING WHEEL, STEER-
ING COLUMN, OR INSTRUMENT PANEL COMPO-
NENTS YOU MUST FIRST DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND)
INJURY.
NEVER STRIKE OR KICK THE AIRBAG CON-
TROL MODULE, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. IF AN AIR-
BAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
further servi ce.
(2) I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pul l the transmi ssi on shi ft l ever handl e
strai ght up fi rml y and qui ckl y to remove the handl e.
I f the vehi cl e i s equi pped wi th a manual transmi s-
si on, remove the shi ft l ever knob by removi ng the
bezel and nut from the top of the knob.
(3) Rel ease the automati c transmi ssi on shi ft i ndi -
cator bezel or the manual transmi ssi on shi ft l ever
boot, and the transfer case shi ft i ndi cator bezel by
pryi ng between the edge of the bezel or boot and the
fl oor consol e wi th a tri m sti ck or another sui tabl e
wi de fl at-bl aded tool (Fi g. 12).
(4) Rai se the shi ft i ndi cator bezel (s) far enough
from the consol e to remove the l amp sockets from the
bezel (s), then remove the bezel (s) and/or boot from
the consol e.
(5) Remove the screws that secure the fl oor consol e
to the consol e and parki ng brake l ever mounti ng
brackets.
(6) Remove the fl oor consol e from the fl oor pan
transmi ssi on tunnel .
(7) Unpl ug the Ai rbag Control Modul e (ACM) wi re
harness connector. To unpl ug the connector, fi rst pul l
the two whi te l ocks out about 3 mm (0.125 i n.) from
each si de of the connector (Fi g. 13). Then squeeze the
two connector l atch tabs between the thumb and
forefi nger, whi l e pul l i ng the connector out from the
ACM.
NOTE: Always remove and replace the airbag con-
trol module and its mounting bracket as a unit.
Replacement modules include a replacement
mounting bracket. Do not transfer the module to
another mounting bracket.
Fig. 10 Inboard Mounting Bolts Remove/Install
A/C HEATER CONTROL OPENING REAR MOUNTING BRACKET REAR BRACKET BOLTS
Fig. 11 Outboard Mounting Bolts Remove/Install
PASSENGER SIDE END OF INSTRUMENT PANEL REAR BRACKET BOLTS REAR MOUNTING BRACKET
(8) Remove the four screws that secure the ACM
mounti ng bracket to the fl oor pan transmi ssi on tun-
nel (Fi g. 14).
(9) Remove the ACM and mounti ng bracket as a
uni t.
(10) When i nstal l i ng the ACM, posi ti on the uni t
wi th the arrow on the ACM housi ng poi nti ng for-
ward.
(11) Attach the ACM to the fl oor pan transmi ssi on
tunnel wi th the four mounti ng screws. Ti ghten the
mounti ng screws to 10.7 Nm (95 i n. l bs.).
(12) Pl ug i n the wi re harness connector to the
ACM. Be certai n that the connector l atches are ful l y
engaged and that the connector l ocks are pushed i n.
CLOCKSPRING
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
INJURY.
Fig. 12 Floor Console Components
SHIFTER INDICATOR TRANSFER CASE SHIFTER BEZEL TRANSFER CASE SHIFTER INDICATOR PARKING BRAKE BEZEL FULL FLOOR CONSOLE PARKING BRAKE CONSOLE BRACKET
Fig. 13 Airbag Control Module Connector Removal
PULL TWO LOCKS OUT
SQUEEZE LATCHES
Fig. 14 Airbag Control Module Remove/Install
SCREWS (4) AIRBAG CONTROL MODULE PARKING BRAKE LEVER FLOOR PAN TRANSMIS- SION TUNNEL
(1) Turn the steeri ng wheel unti l the front wheel s
are i n the strai ght-ahead posi ti on before starti ng the
procedure.
further servi ce.
(3) Remove the ai rbag modul e as descri bed i n thi s
group.
(4) I f the vehi cl e i s so equi pped, unpl ug the wi re
harness connectors for the vehi cl e speed control
swi tches and the remote radi o swi tches.
(5) Remove the steeri ng wheel wi th a steeri ng
wheel pul l er (Speci al Tool C-3428B).
shrouds to gai n access to the cl ockspri ng wi re har-
ness connectors (Fi g. 15).
cl ockspri ng.
(9) Unpl ug the wi re harness connector between the
cl ockspri ng and the i nstrument panel wi re harness,
l ocated near the base of the steeri ng col umn.
(10) To remove the cl ockspri ng, l i ft the l ocati ng
fi ngers of the cl ockspri ng assembl y from the steeri ng
col umn as necessary. The cl ockspri ng cannot be
repai red. I t must be repl aced i f faul ty, or i f the ai r-
bag has been depl oyed.
(11) When i nstal l i ng the cl ockspri ng, snap the
cl ockspri ng onto the steeri ng col umn. I f the cl ock-
spri ng i s not properl y posi ti oned, see Cl ockspri ng
Centeri ng i n thi s group before i nstal l i ng the steeri ng
wheel .
(12) Pl ug the cl ockspri ng wi re harness connector
i nto the i nstrument panel wi re harness. Be certai n
that the wi re harness l ocator cl i ps are properl y
seated on the outsi de of the wi ri ng trough and that
the connector l atches are ful l y engaged.
(13) Rei nstal l the steeri ng col umn shrouds. Be cer-
tai n that the cl ockspri ng wi re harness i s i nsi de the
shrouds.
(14) The front wheel s shoul d sti l l be i n the
strai ght-ahead posi ti on. I nstal l the steeri ng wheel
bei ng certai n to fi t the fl ats on the hub of the steer-
i ng wheel onto the formati ons on the i nsi de of the
cl ockspri ng. Pul l the wi re harnesses from the cl ock-
spri ng through the upper and l ower hol es i n the
steeri ng wheel hub. Ti ghten the steeri ng wheel nut
to 61 Nm (45 ft. l bs.). Be certai n not to pi nch the
wi ri ng between the steeri ng wheel and the nut.
(15) I f the vehi cl e i s so equi pped, pl ug i n the vehi -
cl e speed control swi tch and remote radi o swi tch wi re
harness connectors.
(16) I nstal l the ai rbag modul e as descri bed i n thi s
group.
ADJ USTMENTS
CLOCKSPRING CENTERING
I f the rotati ng tape wi thi n the cl ockspri ng i s not
posi ti oned properl y i n rel ati on to the steeri ng wheel
and the front wheel s, the cl ockspri ng may fai l duri ng
use. The cl ockspri ng must be centered i f i t i s not
known to be properl y posi ti oned, or i f the front
wheel s were moved from the strai ght-ahead posi ti on
wi th the cl ockspri ng removed duri ng any servi ce pro-
cedure.
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
INJURY.
(1) Turn the steeri ng wheel unti l the front wheel s
are i n the strai ght-ahead posi ti on before starti ng the
centeri ng procedure.
Typical
NUT TILT LEVER UPPER SHROUD LOWER SHROUD SCREWS CLOCK SPRING STEERING WHEEL
further servi ce.
(3) Remove the ai rbag modul e as descri bed i n thi s
group.
(4) I f the vehi cl e i s so equi pped, unpl ug the wi re
harness connectors from the vehi cl e speed control
swi tches and the remote radi o swi tches.
(5) Remove the steeri ng wheel wi th a steeri ng
wheel pul l er (Speci al Tool C-3428B).
(6) Depress the two pl asti c cl ockspri ng auto-l ock-
i ng tabs (Fi g. 16).
(7) Keepi ng the l ocki ng mechani sm di sengaged,
rotate the cl ockspri ng rotor cl ockwi se to the end of
i ts travel . Do not appl y excessi ve torque.
(8) From the end of the cl ockwi se travel , rotate the
rotor two and one-hal f turns countercl ockwi se. The
horn wi re harness shoul d end up at the top, and the
ai rbag wi re harness at the bottom.
(9) The front wheel s shoul d sti l l be i n the strai ght-
ahead posi ti on. I nstal l the steeri ng wheel bei ng cer-
tai n to fi t the fl ats on the hub of the steeri ng wheel
onto the formati ons on the i nsi de of the cl ockspri ng.
Pul l the wi re harnesses from the cl ockspri ng through
the upper and l ower hol es i n the steeri ng wheel hub.
Ti ghten the steeri ng wheel nut to 61 Nm (45 ft. l bs.).
Be certai n not to pi nch any of the wi ri ng between the
steeri ng wheel and the nut.
(10) I f the vehi cl e i s so equi pped, pl ug i n the vehi -
cl e speed control swi tch and remote radi o swi tch wi re
harness connectors.
(11) I nstal l the ai rbag modul e as descri bed i n thi s
group.
Fig. 16 Clockspring Auto-Locking Tabs
ELECTRICALLY HEATED SYSTEMS
CONTENTS
page page
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . . . 1 HEATED SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DEFOGGER SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . 2
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . 2
HEATED MIRROR . . . . . . . . . . . . . . . . . . . . . . . 2
REAR GLASS HEATING GRID . . . . . . . . . . . . . . 2
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . 4
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . 4
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . . 3
REAR GLASS HEATING GRID . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
REAR GLASS HEATING GRID REPAIR . . . . . . . 5
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . 6
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . 6
GENERAL INFORMATION
INTRODUCTION
An el ectri cal l y heated rear wi ndow defogger and
el ectri cal l y heated outsi de rear vi ew mi rrors are
standard factory-i nstal l ed equi pment on thi s model .
The defogger wi l l onl y operate when the i gni ti on
swi tch i s i n the On posi ti on. When the defogger
swi tch i s i n the On posi ti on, el ectri c heater gri ds on
the rear wi ndow gl ass and behi nd the outsi de rear
vi ew mi rror gl ass are energi zed. These gri ds produce
heat to hel p cl ear the rear wi ndow gl ass and outsi de
rear vi ew mi rrors of i ce, snow, or fog.
Thi s defogger system i s control l ed by a swi tch
l ocated i nboard of the steeri ng col umn i n the i nboard
swi tch pod on the i nstrument panel . A Li ght-Emi t-
ti ng Di ode (LED) above the swi tch button i n the
swi tch pod wi l l l i ght to i ndi cate when the defogger
system i s turned on. The Body Control Modul e
(BCM), whi ch contai ns the defogger system ti mer
l ogi c, moni tors the state of the defogger swi tch
through a hard-wi red i nput. The BCM ci rcui try con-
trol s the defogger system through a hard-wi red con-
trol output to the defogger rel ay.
The defogger system wi l l be automati cal l y turned
off after a programmed ti me i nterval of about ten
mi nutes. After the i ni ti al ti me i nterval has expi red, i f
the defogger swi tch i s turned on agai n duri ng the
same i gni ti on cycl e, the defogger system wi l l auto-
mati cal l y turn off after about fi ve mi nutes.
The defogger system wi l l automati cal l y shut off i f
the i gni ti on swi tch i s turned to the Off posi ti on, or i t
can be turned off manual l y by depressi ng the i nstru-
ment panel swi tch. Refer to the owners manual for
more i nformati on on the defogger system control s
and operati on.
components i n the defogger system. Refer to 8W-48 -
Rear Wi ndow Defogger and 8W-62 - Power Mi rrors i n
ZG ELECTRICALLY HEATED SYSTEMS 8N - 1
REAR GLASS HEATING GRID
The heated rear wi ndow gl ass has two el ectri cal l y
conducti ve verti cal bus bars and a seri es of hori zon-
tal gri d l i nes made of a si l ver-cerami c materi al ,
whi ch i s baked on and bonded to the i nsi de surface of
the gl ass. The gri d l i nes and bus bars compri se a
paral l el el ectri cal ci rcui t.
When the rear wi ndow defogger swi tch i s pl aced i n
the On posi ti on, el ectri cal current i s di rected to the
rear wi ndow gri d l i nes through the bus bars. The
gri d l i nes heat the rear wi ndow to cl ear the surface
of fog or snow. Protecti on for the heated gri d ci rcui t
i s provi ded by a fuse i n the juncti on bl ock.
The gri d l i nes and bus bars are hi ghl y resi stant to
abrasi on. However, i t i s possi bl e for an open ci rcui t
to occur i n an i ndi vi dual gri d l i ne, resul ti ng i n no
current fl ow through the l i ne.
The gri d l i nes can be damaged or scraped off wi th
sharp i nstruments. Care shoul d be taken when cl ean-
i ng the gl ass or removi ng forei gn materi al s, decal s,
or sti ckers from the gl ass. Normal gl ass cl eani ng sol -
vents or hot water used wi th rags or towel i ng i s rec-
ommended.
A repai r ki t i s avai l abl e to repai r the gri d l i nes and
bus bars, or to rei nstal l the heated gl ass pi gtai l
wi res.
HEATED MIRROR
The heated mi rrors are control l ed by the rear wi n-
dow defogger swi tch. The heater el ements i n the mi r-
ror are acti vated onl y when the rear wi ndow defogger
swi tch i s i n the On posi ti on. The heater el ements i n
the mi rrors cannot be repai red and, i f faul ty, the
enti re mi rror uni t must be repl aced. Refer to Group
8T - Power Mi rrors for the di agnosi s and servi ce of
thi s component.
DEFOGGER SWITCH
The rear wi ndow defogger swi tch i s mounted i n the
i nboard i nstrument panel swi tch pod, i nboard of the
steeri ng col umn. The momentary-type swi tch pro-
vi des a hard-wi red ground si gnal to the Body Control
Modul e (BCM) each ti me i t i s depressed. The BCM
rear wi ndow defogger ti mer and l ogi c ci rcui try
responds by energi zi ng or de-energi zi ng the rear wi n-
dow defogger rel ay.
Energi zi ng the rear wi ndow defogger rel ay pro-
vi des el ectri cal current to the rear wi ndow defogger
gri d and the Li ght-Emi tti ng Di ode (LED) i ndi cator i n
the swi tch, whi ch l i ghts to i ndi cate that the defogger
system i s turned On. The defogger swi tch and LED
cannot be repai red and, i f faul ty, the i nboard swi tch
pod uni t must be repl aced.
DEFOGGER RELAY
The rear wi ndow defogger rel ay i s a I nternati onal
Standards Organi zati on (I SO)-type rel ay. The rear
wi ndow defogger rel ay i s a el ectromechani cal devi ce
that swi tches fused battery current to the rear gl ass
heati ng gri d and the Li ght-Emi tti ng Di ode (LED)
i ndi cator of the defogger swi tch, when the Body Con-
trol Modul e (BCM) rear wi ndow defogger ti mer and
l ogi c ci rcui try grounds the rel ay coi l . See the Di agno-
si s and Testi ng secti on of thi s group for more i nfor-
mati on on the operati on of the rear wi ndow defogger
rel ay.
The rear wi ndow defogger rel ay i s l ocated i n the
juncti on bl ock, on the ri ght cowl si de panel bel ow the
i nstrument panel i n the passenger compartment.
The rear wi ndow defogger rel ay cannot be repai red
BODY CONTROL MODULE
One of the systems that the BCM supports and
control s, i s the rear wi ndow defogger system. I n i ts
rol e as the defogger system ti mer and control l er, the
BCM recei ves hard-wi red i nputs from the defogger
swi tch and the i gni ti on swi tch. The programmi ng i n
the BCM al l ows i t to process the i nformati on from
these i nputs and send a control output to energi ze or
de-energi ze the defogger rel ay. The BCM al so sends a
defogger swi tch status message to the Dri ver Door
Modul e (DDM) and Passenger Door Modul e (PDM)
on the CCD data bus. The DDM and PDM respond
8N - 2 ELECTRICALLY HEATED SYSTEMS ZG
by control l i ng the current feeds to thei r respecti ve
outsi de rear vi ew mi rror heati ng el ements.
DEFOGGER SYSTEM
8W-48 - Rear Wi ndow Defogger i n Group 8W - Wi r-
i ng Di agrams. The operati on of the el ectri cal l y
heated rear wi ndow defogger system can be con-
fi rmed i n one of the fol l owi ng manners:
1. Turn the i gni ti on swi tch to the On posi ti on.
Whi l e moni tori ng the i nstrument panel vol tmeter, set
the defogger swi tch i n the On posi ti on. When the
defogger swi tch i s turned On, a di sti nct vol tmeter
needl e defl ecti on shoul d be noted.
2. Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The rear wi n-
dow defogger operati on can be checked by feel i ng the
rear wi ndow or outsi de rear vi ew mi rror gl ass. A di s-
ti nct di fference i n temperature between the gri d l i nes
and the adjacent cl ear gl ass or the mi rror gl ass can
be detected wi thi n three to four mi nutes of operati on.
3. Usi ng a 12-vol t DC vol tmeter, contact the rear
gl ass heati ng gri d termi nal A (ri ght si de) wi th the
negati ve l ead, and termi nal B (l eft si de) wi th the pos-
i ti ve l ead (Fi g. 1). The vol tmeter shoul d read battery
vol tage.
The above checks wi l l confi rm system operati on.
I l l umi nati on of the defogger swi tch LED means that
there i s el ectri cal current avai l abl e at the output of
the defogger rel ay, but does not confi rm that the el ec-
tri cal current i s reachi ng the rear gl ass heati ng gri d
l i nes.
I f the defogger system does not operate, the prob-
l em shoul d be i sol ated i n the fol l owi ng manner:
(1) Confi rm that the i gni ti on swi tch i s i n the On
posi ti on.
(2) Ensure that the rear gl ass heati ng gri d feed
and ground wi res are connected to the gl ass. Confi rm
that the ground wi re has conti nui ty to ground.
(3) Check the fuses i n the Power Di stri buti on Cen-
ter (PDC) and i n the juncti on bl ock. The fuses must
be ti ght i n thei r receptacl es and al l el ectri cal connec-
ti ons must be secure.
When the above steps have been compl eted and the
rear gl ass heati ng gri d i s sti l l i noperati ve, one or
more of the fol l owi ng i s faul ty:
Defogger swi tch
Defogger rel ay
Body Control Modul e (BCM)
Rear wi ndow gri d l i nes (al l gri d l i nes woul d
have to be broken or one of the feed wi res di scon-
nected for the enti re system to be i noperati ve).
When the above steps have been compl eted and the
heated mi rror gl ass heati ng el ement i s sti l l i nopera-
ti ve, one or more of the fol l owi ng i s faul ty:
Body Control Modul e (BCM)
Chrysl er Col l i si on Detecti on (CCD) data bus
Dri ver or passenger door modul e
Outsi de rear vi ew mi rror heati ng el ements.
I f setti ng the defogger swi tch to the On posi ti on
produces a severe vol tmeter defl ecti on, check for a
short ci rcui t between the defogger rel ay output and
the rear gl ass heati ng gri d.
REAR GLASS HEATING GRID
i ng Di agrams. To detect breaks i n the gri d l i nes, the
fol l owi ng procedure i s requi red:
(1) Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The i ndi cator
l amp shoul d l i ght. I f OK, go to Step 2. I f not OK, see
the Defogger Rel ay di agnosi s i n thi s group.
(2) Usi ng a 12-vol t DC vol tmeter, contact the ver-
ti cal bus bar on the ri ght si de of the vehi cl e wi th the
negati ve l ead. Wi th the posi ti ve l ead, contact the ver-
ti cal bus bar on the l eft si de of the vehi cl e. The vol t-
meter shoul d read battery vol tage. I f OK, go to Step
3. I f not OK, repai r the open ci rcui t to the defogger
rel ay as requi red.
(3) Wi th the negati ve l ead of the vol tmeter, contact
a good body ground poi nt. The vol tage readi ng shoul d
Fig. 1 Rear Window Glass Grid Test
TERMINALA VOLTMETER TERMINALB FEED WIRE MID-POINT C (TYPICAL) HEATED REAR WINDOW DEFOGGER GRID GROUND WIRE
not change. I f OK, go to Step 4. I f not OK, repai r the
(4) Connect the negati ve l ead of the vol tmeter to
the ri ght si de bus bar and touch each gri d l i ne at
mi dpoi nt C wi th the posi ti ve l ead. A readi ng of
approxi matel y si x vol ts i ndi cates a l i ne i s good. A
readi ng of zero vol ts i ndi cates a break i n the gri d
l i ne between mi dpoi nt C and the l eft si de bus bar. A
readi ng of ten to fourteen vol ts i ndi cates a break
between mi dpoi nt C and the ri ght si de bus bar. Move
the posi ti ve l ead on the gri d l i ne towards the break
and the vol tage readi ng wi l l change as soon as the
break i s crossed.
DEFOGGER SWITCH
i ng Di agrams.
INJURY.
cabl e. Remove the i nboard i nstrument panel swi tch
pod and unpl ug the swi tch pod 10-way wi re harness
connector.
cui t cavi ty of the swi tch pod 10-way wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 3. I f not OK, repai r the open
(3) Connect two jumper wi res to the i nboard
swi tch pod as fol l ows. Connect the ground ci rcui t ter-
mi nal i n the 10-way wi re harness connector recepta-
cl e on the back of the i nboard swi tch pod housi ng to
a good ground. Connect the fused rear wi ndow defog-
ger rel ay output ci rcui t termi nal of the 10-way wi re
harness connector receptacl e to a 12-vol t battery
feed. The defogger swi tch LED i ndi cator shoul d l i ght.
i nboard swi tch pod.
cui t and rear wi ndow defogger swi tch sense ci rcui t
termi nal s of the 10-way wi re harness connector
receptacl e on the back of the i nboard swi tch pod
housi ng. There shoul d be momentary conti nui ty as
the defogger swi tch button i s depressed, and then no
conti nui ty. I f OK, go to Step 5. I f not OK, repl ace the
faul ty i nboard swi tch pod.
(5) Unpl ug the whi te 24-way wi re harness connec-
conti nui ty between the rear wi ndow defogger swi tch
sense ci rcui t cavi ty of the i nboard swi tch pod 10-way
shoul d be no conti nui ty. I f OK, go to Step 6. I f not
OK, repai r the short ci rcui t as requi red.
(6) Check for conti nui ty between the rear wi ndow
defogger swi tch sense ci rcui t cavi ti es of the i nboard
swi tch pod 10-way wi re harness connector and the
BCM whi te 24-way wi re harness connector. There
shoul d be conti nui ty. I f OK, see the Defogger Rel ay
DEFOGGER RELAY
INJURY.
RELAY TEST
The defogger rel ay i s l ocated i n the juncti on bl ock,
on the ri ght cowl si de panel bel ow the i nstrument
panel i n the passenger compartment. Remove the
defogger rel ay from the juncti on bl ock as descri bed i n
thi s group to perform the fol l owi ng tests:
tromagnet) shoul d be 75 10 ohms. I f OK, go to
Step 3. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
to the fuse i n the juncti on bl ock that feeds the rear
gl ass heati ng gri d and the defogger swi tch LED i ndi -
cator. There shoul d be conti nui ty between the cavi ty
for rel ay termi nal 87 and the rear gl ass heati ng gri d
and defogger swi tch LED i ndi cator at al l ti mes. I f
OK, go to Step 4. I f not OK, repai r the open ci rcui t
as requi red.
the el ectromagnet i n the rel ay. I t i s connected to bat-
tery vol tage and shoul d be hot at al l ti mes. Check for
battery vol tage at the cavi ty for rel ay termi nal 86. I f
the PDC fuse as requi red.
the el ectromagnet i n the rel ay. Thi s termi nal i s pro-
vi ded wi th ground by the Body Control Modul e
(BCM) rear wi ndow defogger ti mer and l ogi c ci rcui try
to energi ze the defogger rel ay. There shoul d be conti -
nui ty to the rear wi ndow defogger rel ay control ci r-
connector. I f OK, use a DRB scan tool and the proper
Di agnosti c Procedures manual to test the BCM. I f
SERVICE PROCEDURES
REAR GLASS HEATING GRID REPAIR
Repai r of the gri d l i nes, bus bars, or pi gtai l wi res
can be accompl i shed usi ng a Mopar Rear Wi ndow
Defogger Repai r Ki t (P/N 4267922) or equi val ent.
WARNING: MATERIALS CONTAINED IN THE
REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.
THE KIT CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, WHICH ARE HARMFUL IF SWAL-
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) Mask the repai r area so that the conducti ve
epoxy can be appl i ed neatl y. Extend the epoxy appl i -
cati on onto the gri d l i ne or the bus bar on each si de
of the break (Fi g. 2).
(2) Fol l ow the i nstructi ons i n the repai r ki t for
prepari ng the damaged area.
(3) Remove the package separator cl amp and mi x
the two conducti ve epoxy components thoroughl y
wi thi n the packagi ng. Fol d the package i n hal f and
cut the center corner to di spense the epoxy.
(4) For gri d l i ne repai rs, mask the area to be
repai red wi th maski ng tape or a templ ate.
(5) Appl y the epoxy through the sl i t i n the mask-
i ng tape or templ ate. Overl ap both ends of the break
by at l east 19 mm (0.75 i n.).
(6) For a termi nal or pi gtai l wi re repl acement,
mask the adjacent areas so the epoxy can be
extended onto the adjacent gri d l i ne as wel l as the
bus bar. Appl y a thi n l ayer of epoxy to the area
where the termi nal or pi gtai l wi re was fastened and
onto the adjacent gri d l i ne.
(7) Appl y a thi n l ayer of conducti ve epoxy to the
termi nal or bare wi re end of the pi gtai l and pl ace i t
i n the proper l ocati on on the bus bar. To prevent the
termi nal or pi gtai l wi re from movi ng whi l e the epoxy
i s curi ng, i t must be wedged or cl amped.
(8) Careful l y remove the maski ng tape or tem-
pl ate.
CAUTION: Do not allow the glass surface to exceed
204 C (400 F) or the glass may fracture.
Defogger Relay
RELAY TERMINALS RELAY CAVITIES
Fig. 2 Grid Line Repair - Typical
BREAK GRID LINE MASKING TAPE
(9) Al l ow the epoxy to cure 24 hours at room tem-
perature, or use a heat gun wi th a 260 to 371 C
(500 to 700 F) range for fi fteen mi nutes. Hol d the
heat gun approxi matel y 254 mm (10 i n.) from the
repai r.
(10) After the conducti ve epoxy i s properl y cured,
remove the wedge or cl amp from the termi nal or pi g-
tai l wi re. Do not attach the wi re harness connectors
unti l the curi ng process i s compl ete.
(11) Check the operati on of the rear wi ndow defog-
ger rear gl ass heati ng gri d.
DEFOGGER SWITCH
INJURY.
cabl e.
i nstrument panel far enough to access the wi re har-
ness connectors.
i nboard swi tch pod.
i nstrument panel .
DEFOGGER RELAY
INJURY.
cabl e.
cowl si de tri m to the juncti on bl ock stud (Fi g. 4).
tri m.
(6) Unpl ug the defogger rel ay from the juncti on
bl ock.
(7) I nstal l the defogger rel ay by al i gni ng the rel ay
termi nal s wi th the cavi ti es i n the juncti on bl ock and
fuse access panel .
HEATED SEATS
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 7
HEATED SEAT CONTROL MODULE . . . . . . . . . 8
HEATED SEAT ELEMENT AND SENSOR . . . . . . 8
HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . . 7
HEATED SEAT CONTROL MODULE . . . . . . . . . 9
HEATED SEAT ELEMENT . . . . . . . . . . . . . . . . . 9
HEATED SEAT SENSOR . . . . . . . . . . . . . . . . . . 9
HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . 8
HEATED SEAT CONTROL MODULE . . . . . . . . 10
GENERAL INFORMATION
INTRODUCTION
I ndi vi dual l y control l ed el ectri cal l y heated front
seats are avai l abl e factory-i nstal l ed opti onal equi p-
ment on thi s model . The seat heaters wi l l onl y oper-
ate when the i gni ti on swi tch i s i n the On posi ti on,
and the surface temperature at the front seat heati ng
el ement sensors i s bel ow the desi gned temperature
set poi nts of the system. The heated seat system wi l l
not operate i n ambi ent temperatures greater than
about 32C (90F).
There are separate three-posi ti on swi tches for each
front seat l ocated i n the i nboard i nstrument panel
swi tch pod, just i nboard of the steeri ng col umn. An
Off, Low, or Hi gh posi ti on can be sel ected wi th each
swi tch, and Li ght-Emi tti ng Di odes (LED) for each
swi tch i l l umi nate to gi ve a vi sual i ndi cati on that the
system i s turned on. The Low heat posi ti on set poi nt
i s about 32C (90F), and the Hi gh heat posi ti on set
poi nt i s about 38C (100F). Each swi tch control s a
Heated Seat Control Modul e (HSCM) mounted to the
seat cushi on frame under each front seat.
When a seat heater i s turned on, a sensor l ocated
near the seat cushi on el ectri c heater el ement pro-
vi des the HSCM wi th an i nput i ndi cati ng the surface
temperature of the seat cushi on. I f the surface tem-
perature i nput i s bel ow the temperature set poi nt for
the sel ected Low or Hi gh swi tch posi ti on, a rel ay
wi thi n the HSCM energi zes the heati ng el ements i n
the seat cushi on and back. When the sensor i nput
i ndi cates the correct temperature set poi nt has been
achi eved, the HSCM de-energi zes the rel ay. The
HSCM wi l l conti nue to cycl e the rel ay as needed to
mai ntai n the temperature set poi nt.
The HSCM wi l l automati cal l y turn off the heati ng
el ements i f i t detects an open i n the sensor ci rcui t, or
a short i n the heati ng el ement ci rcui t causi ng an
excessi ve current draw. The system i s al so turned off
automati cal l y when the i gni ti on swi tch i s turned to
the Off posi ti on. The control ci rcui t operates on i gni -
ti on swi tched battery feed through a fuse i n the junc-
ti on bl ock. The heati ng el ements operate on battery
feed suppl i ed through the power seat ci rcui t breaker
i n the juncti on bl ock.
components i n the heated seat system. Refer to
8W-63 - Power Seat Wi th Heated Seats i n Group 8W
- Wi ri ng Di agrams for compl ete ci rcui t descri pti ons
and di agrams.
HEATED SEAT SWITCH
The heated seat swi tch i s i ntegral to the i nboard
swi tch pod, whi ch i s mounted i n the i nstrument
panel just i nboard of the steeri ng col umn. The two
three-posi ti on sl i di ng-type swi tches, one swi tch for
each front seat, provi de a resi stor mul ti pl exed si gnal
to thei r respecti ve Heated Seat Control Modul e
(HSCM). Each swi tch has an Off, Low, and Hi gh
posi ti on so that both the dri ver and the front seat
passenger can sel ect a preferred seat heati ng mode.
Each swi tch has a Li ght-Emi tti ng Di ode (LED),
whi ch l i ghts to i ndi cate that the seat heater that the
swi tch control s i s turned on. The heated seat
swi tches and thei r LED cannot be repai red. I f ei ther
swi tch or LED i s faul ty, the i nboard swi tch pod uni t
must be repl aced.
HEATED SEAT CONTROL MODULE
The Heated Seat Control Modul e (HSCM) i s an
el ectroni c thermostati c modul e desi gned to operate
the el ectri c seat heater el ements. Two modul es are
used i n the vehi cl e, one for each front seat. The
HSCM for each seat i s mounted to a bracket under
the seat cushi on spri ng. The bracket i s secured to the
i nsi de surface of the outboard seat cushi on frame
wi th a si ngl e screw dri ven through the frame from
the outsi de.
I nputs to the modul e i ncl ude the mul ti pl ex resi stor
i nstrument panel swi tch si gnal s (whi ch i ncl udes the
seat cushi on temperature sensor ci rcui ts), an i gni -
ti on-swi tched battery feed, a non-swi tched battery
feed, and a ground. The onl y HSCM output i s the
feed for the seat heati ng el ements.
The HSCM cannot be repai red and, i f faul ty, i t
must be repl aced.
HEATED SEAT ELEMENT AND SENSOR
Two heated seat heati ng el ements are used i n each
front seat, one for the seat cushi on and the other for
the seat back. The two el ements for each seat are
connected i n seri es wi th the HSCM.
The temperature sensor i s a Negati ve Temperature
Coeffi ci ent (NTC) thermi stor. One temperature sen-
sor i s used for each seat, and i t i s i ntegrated i nto the
seat cushi on heati ng el ement.
The heati ng el ements are sewn i nto the seat cush-
i on cover and seat back cover assembl i es, whi ch are
servi ced i ndi vi dual l y. The heati ng el ements and tem-
perature sensor cannot be repai red and, i f faul ty, the
affected seat cover assembl y must be repl aced. Refer
to Group 23 - Body for the seat cover servi ce proce-
dures.
HEATED SEAT SYSTEM
- Wi ri ng Di agrams.
INJURY.
Before testi ng the i ndi vi dual components i n the
heated seat system, check the fol l owi ng:
I f the heated seat swi tch LED doesnt l i ght wi th
the i gni ti on swi tch i n the On posi ti on and the heated
seat swi tch i n the Low or Hi gh posi ti on, check the
fuse i n the juncti on bl ock. I f the fuse i s OK, test the
heated seat swi tch as descri bed i n thi s group.
I f the heated seat swi tch LED l i ghts, but the
heati ng el ements dont heat, check the ci rcui t
breaker i n the juncti on bl ock. I f the ci rcui t breaker i s
OK, test the heated seat el ements as descri bed i n
thi s group.
HEATED SEAT SWITCH
- Wi ri ng Di agrams.
INJURY.
cabl e.
(2) Remove the i nboard swi tch pod as descri bed i n
thi s group. Unpl ug the 10-way wi re harness connec-
tor from the swi tch pod. Check for conti nui ty
between the ground ci rcui t cavi ty of the 10-way
swi tch pod wi re harness connector and a good
vol tage at the fused i gni ti on swi tch output ci rcui t
cavi ty of the 10-way swi tch pod wi re harness connec-
Unpl ug the remai ni ng i nboard swi tch pod wi re har-
ness connectors and remove the i nboard swi tch pod
from the i nstrument panel .
(5) Wi th both heated seat swi tches i n the Off posi -
ti on, check for conti nui ty between the fused i gni ti on
swi tch output ci rcui t termi nal and the dri ver heated
seat swi tch output ci rcui t termi nal i n the 10-way
connector receptacl e on the back of the i nboard
swi tch pod. Repeat thi s check between the fused i gni -
ti on swi tch output ci rcui t termi nal and the passenger
heated seat swi tch output ci rcui t termi nal . I n each
case, there shoul d be no conti nui ty. I f OK, go to Step
6. I f not OK, repl ace the faul ty i nboard swi tch pod.
(6) Move both heated seat swi tches to the Low
posi ti on. Usi ng an ohmmeter, check the resi stance
between the fused i gni ti on swi tch output ci rcui t ter-
mi nal and the dri ver heated seat swi tch output ci r-
cui t termi nal i n the 10-way connector receptacl e on
the back of the i nboard swi tch pod. Repeat thi s check
mi nal and the passenger heated seat swi tch output
ci rcui t termi nal . I n each case, the resi stance readi ng
shoul d be about 11.5 ki l ohms. I f OK, go to Step 7. I f
not OK, repl ace the faul ty i nboard swi tch pod.
(7) Move both heated seat swi tches to the Hi gh
posi ti on. Usi ng an ohmmeter, check the resi stance
mi nal and the dri ver heated seat swi tch output ci r-
cui t termi nal i n the 10-way connector receptacl e on
the back of the i nboard swi tch pod. Repeat thi s check
mi nal and the passenger heated seat swi tch output
ci rcui t termi nal . I n each case, the resi stance readi ng
shoul d be about 6.5 ki l ohms. I f not OK, repl ace the
faul ty i nboard swi tch pod.
Before testi ng the heated seat control modul e, test
the heated seat swi tch, the heated seat el ements, and
the heated seat sensor as descri bed i n thi s group. I f
testi ng of the heated seat swi tch, el ements, and sen-
sor reveal s no probl ems, repl ace the heated seat con-
trol modul e wi th a known good uni t and test the
operati on of the heated seats. I f OK, di scard the
faul ty heated seat control modul e. I f not OK, test the
ci rcui ts from the heated seat swi tch, el ements, and
sensor to the heated seat control modul e. Repai r any
short or open ci rcui ts as requi red. For ci rcui t descri p-
ti ons and di agrams, refer to 8W-63 - Power Seat
Wi th Heated Seats i n Group 8W - Wi ri ng Di agrams.
HEATED SEAT ELEMENT
The wi re harness connectors for the seat cushi on
and seat back heati ng el ements are l ocated under the
seat, near the rear edge of the seat cushi on frame.
- Power Seat Wi th Heated Seats i n Group 8W - Wi r-
i ng Di agrams.
SEAT CUSHION
cabl e. Unpl ug the 4-way heated seat cushi on wi re
harness connector.
(2) Check for conti nui ty between the two heated
seat dri ver ci rcui t cavi ti es of the seat cover hal f of
the heated seat cushi on wi re harness connector.
There shoul d be conti nui ty. I f OK, go to Step 3. I f not
OK, repl ace the faul ty seat cushi on cover.
(3) Check for conti nui ty between one of the heated
seat dri ver ci rcui t cavi ti es of the seat cover hal f of
the heated seat cushi on wi re harness connector and
the seat cushi on frame. There shoul d be no conti nu-
i ty. I f OK, test the seat back el ement. I f not OK,
repl ace the faul ty seat cushi on cover.
SEAT BACK
cabl e. Unpl ug the 2-way heated seat back wi re har-
ness connector.
(2) Check for conti nui ty between the heated seat
dri ver ci rcui t cavi ty and the ground ci rcui t cavi ty of
the seat cover hal f of the heated seat back wi re har-
ness connector. There shoul d be conti nui ty. I f OK, go
to Step 3. I f not OK, repl ace the faul ty seat back
cover.
(3) Check for conti nui ty between the heated seat
dri ver ci rcui t cavi ty of the seat cover hal f of the
heated seat back wi re harness connector and the seat
back frame. There shoul d be no conti nui ty. I f OK,
test the heated seat sensor as descri bed i n thi s
group. I f not OK, repl ace the faul ty seat back cover.
HEATED SEAT SENSOR
The wi re harness connector for the seat cushi on
heati ng el ement and sensor are l ocated under the
seat, near the rear edge of the seat cushi on frame.
- Power Seat Wi th Heated Seats i n Group 8W - Wi r-
i ng Di agrams.
cabl e. Unpl ug the 4-way heated seat cushi on wi re
harness connector.
(2) Usi ng an ohmmeter, check the resi stance
between the heated seat swi tch output ci rcui t cavi ty
and the ground ci rcui t cavi ty of the seat cover hal f of
the heated seat cushi on wi re harness connector. The
sensor resi stance shoul d be between 2 ki l ohms and
200 ki l ohms. I f OK, test the heated seat control mod-
ul e as descri bed i n thi s group. I f not OK, repl ace the
faul ty seat cushi on cover.
HEATED SEAT SWITCH
INJURY.
cabl e.
bl aded tool , pry gentl y around the edges of the
ness connectors.
i nstrument panel .
(1) Move the power seat adjuster to i ts ful l up and
ful l forward stop posi ti ons.
(2) Remove the three screws that secure the seat
si de shi el d to the seat cushi on frame.
(3) Pul l the seat si de shi el d away from the seat far
enough so that the power recl i ner adjuster l ower
bracket can be seen.
(4) Adjust the seat back wi th the power recl i ner
swi tch so that both of the two bol ts i n the power
recl i ner adjuster l ower bracket can be accessed.
cabl e.
(6) Remove the two bol ts that secure the power
recl i ner adjuster l ower bracket to the seat cushi on
frame.
(7) Gentl y pry the power recl i ner adjuster l ower
bracket upwards to access the heated seat control
modul e mounti ng screw (Fi g. 2).
(8) Remove the heated seat control modul e mount-
i ng screw from the seat cushi on frame.
(9) Reach under the rear of the seat cushi on to
l ower the heated seat control modul e and mounti ng
bracket uni t from the i nsi de of the seat cushi on
frame (Fi g. 3).
(10) Unpl ug the heated seat control modul e wi re
harness connector and remove the modul e from
under the seat.
Ti ghten the power recl i ner adjuster l ower bracket
bol ts to 28 Nm (20 ft. l bs.).
Fig. 2 Heated Seat Control Module Remove/Install
POWER RECLINER ADJUSTER HEATED SEAT CONTROL MODULE MOUNTING SCREW SEAT CUSHION FRAME
Fig. 3 Heated Seat Control Module
HEATED SEAT CONTROL MODULE SEAT CUSHION FRAME
POWER LOCK SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2
POWER LIFTGLASS RELEASE SYSTEM . . . . . . 1
POWER LOCK SYSTEM . . . . . . . . . . . . . . . . . . 1
REMOTE KEYLESS ENTRY SYSTEM . . . . . . . . 2
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 3
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . 3
POWER LOCK SWITCH . . . . . . . . . . . . . . . . . . . 2
REMOTE KEYLESS ENTRY RECEIVER . . . . . . . 4
REMOTE KEYLESS ENTRY TRANSMITTER . . . 3
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 4
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER LIFTGLASS RELEASE SYSTEM . . . . . . 5
POWER LOCK AND REMOTE KEYLESS ENTRY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . 5
REMOTE KEYLESS ENTRY TRANSMITTER . . . 5
SERVICE PROCEDURES
REMOTE KEYLESS ENTRY TRANSMITTER
BATTERY REPLACEMENT . . . . . . . . . . . . . . . 6
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 6
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
INTRODUCTION
Power l ocks and Remote Keyl ess Entry (RKE) sys-
tems are standard factory-i nstal l ed equi pment on
these model s. Al l of the doors and the l i ftgate can be
l ocked and unl ocked el ectri cal l y by operati ng the
swi tch on ei ther front door tri m panel , or the buttons
on the RKE transmi tter. On vehi cl es wi th the
opti onal l i ftgate l i ftgl ass, the power l i ftgl ass rel ease
ci rcui t i s al so enabl ed or di sabl ed by the power door
l ock swi tch or the RKE transmi tter.
components i n the power l ock, RKE, and l i ftgl ass
l atch systems. Refer to 8W-61 - Power Door Locks i n
descri pti ons and di agrams. Refer to the owners man-
ual for more i nformati on on the features and use of
these systems.
POWER LOCK SYSTEM
The power l ock system al l ows al l of the doors and
the l i ftgate to be l ocked or unl ocked el ectri cal l y by
operati ng the swi tch on ei ther front door tri m panel .
Thi s system operates wi th battery power suppl i ed
through a ci rcui t breaker i n the juncti on bl ock, i nde-
pendent of the i gni ti on swi tch.
The power l ock system i ncl udes the front door
power l ock swi tches, door modul es mounted i n each
front door, and the power l ock motors mounted i n
each door and the l i ftgate.
POWER LIFTGLASS RELEASE SYSTEM
Model s equi pped wi th the opti onal l i ftgate l i ftgl ass
feature al so have a power operated l i ftgl ass rel ease
system. Thi s system operates wi th battery power
suppl i ed through a fuse i n the juncti on bl ock, i nde-
pendent of the i gni ti on swi tch. The power l i ftgl ass
rel ease system al l ows the l i ftgl ass to be opened by
depressi ng a swi tch mounted i n the top of the l i ftgate
l i cense pl ate tub.
The l i ftgl ass rel ease system i ncl udes the l i ftgate
mounted swi tch, a mechani cal l atch equi pped wi th
an el ectri c rel ease sol enoi d, and a l i mi t swi tch i nte-
gral to the l i ftgate l atch mechani sm. The l i mi t swi tch
automati cal l y enabl es or di sabl es the l i ftgl ass rel ease
ci rcui try, dependi ng upon the posi ti on of the l i ftgate
l atch l ock mechani sm. The l i ftgate l atch can be
unl ocked or l ocked usi ng the key i n the l i ftgate l ock
cyl i nder, the power l ock system, or the remote key-
l ess entry transmi tter.
ZG POWER LOCK SYSTEMS 8P - 1
Refer to 8W-61 - Power Door Locks i n Group 8W -
grams. Refer to Group 23 - Body for the power l i ft-
gl ass rel ease component servi ce procedures.
REMOTE KEYLESS ENTRY SYSTEM
The Remote Keyl ess Entry (RKE) system i s a radi o
frequency system that al l ows the use of a remote
transmi tter to control the power l ock and i l l umi nated
entry systems. I f the vehi cl e i s so equi pped, the RKE
transmi tter can al so control the memory seat, mem-
ory mi rror, memory radi o, and the vehi cl e theft
al arm systems.
The RKE system consi sts of the remote key fob
transmi tter and a recei ver wi th program l ogi c, whi ch
i s i ntegral to the passenger door modul e. The RKE
system can retai n the vehi cl e access codes of two
transmi tters. The transmi tter codes are retai ned i n
memory, even i f the battery i s di sconnected.
I f a transmi tter i s faul ty or l ost, new transmi tter
vehi cl e access codes can be programmed i nto the sys-
tem usi ng a DRB scan tool and the proper Body
On model s so equi pped, a functi on of the RKE sys-
tem made possi bl e by the connecti on of the passenger
door modul e to the Chrysl er Col l i si on Detecti on
(CCD) data bus network i s a pani c mode. I f the Pani c
button on the transmi tter i s depressed, the horn wi l l
sound and l i ghts wi l l fl ash on the vehi cl e for about
three mi nutes, or unti l any of the three transmi tter
buttons i s depressed. A vehi cl e speed of about 24
ki l ometers-per-hour (15 mi l es-per-hour) wi l l al so can-
cel the pani c mode.
MEMORY SYSTEM
and recal l the dri ver power seat posi ti ons (i ncl udi ng
power l umbar and recl i ner posi ti ons) and both out-
si de power mi rror posi ti ons. For vehi cl es wi th a radi o
connected to the Chrysl er Col l i si on Detecti on (CCD)
data bus network, the memory system i s al so abl e to
store and recal l ten radi o stati on presets (i ncl udi ng
l ast stati on tuned) for two dri vers. The memory sys-
tem wi l l automati cal l y return to al l of these setti ngs
when the correspondi ng button (Dri ver 1 or 2) of the
memory swi tch on the dri ver front door tri m panel i s
depressed, or when the doors are unl ocked usi ng the
correspondi ng (Dri ver 1 or 2) Remote Keyl ess Entry
(RKE) transmi tter.
wi red i nput from the memory swi tch on the dri ver
front door tri m panel . The DDM al so recei ves mes-
sages on the CCD data bus from the RKE recei ver i n
the Passenger Door Modul e (PDM) for the memory
sel ect functi on. The DDM processes these i nputs and
sends messages to the radi o (i f the radi o i s CCD data
bus capabl e), the PDM, and the Memory Seat Modul e
(MSM) on the CCD data bus for memory recal l .
procedures for the power l ock and RKE system com-
ponents. For di agnosi s of the memory system, use of
a DRB scan tool and the proper Body Di agnosti c Pro-
cedures manual are recommended. For addi ti onal
i nformati on on the features and functi ons of the
memory system, refer to the vehi cl e owners manual .
POWER LOCK SWITCH
The power l ocks are control l ed by a two-way swi tch
mounted i n the tri m panel of each front door. Each
swi tch i s i l l umi nated by a l i ght-emi tti ng di ode when
the i gni ti on swi tch i s turned to the On posi ti on.
The power l ock swi tches are i ntegral to the Dri ver
Door Modul e (DDM) or Passenger Door Modul e
(PDM), respecti vel y. The power l ock swi tch provi des
a l ock or unl ock si gnal to the door modul e ci rcui try.
The power l ock swi tches and thei r l amps cannot be
repai red. I f the swi tches are damaged or faul ty, the
enti re door modul e must be repl aced.
DOOR MODULE
A Dri ver Door Modul e (DDM) and a Passenger
Door Modul e (PDM) are used on thi s model to control
and i ntegrate many of the el ectroni c features and
functi ons on the vehi cl e. The DDM and PDM commu-
ni cate wi th each other, and wi th other vehi cl e mod-
ul es on the Chrysl er Col l i si on Detecti on (CCD) data
bus network.
ness compl exi ty, i nternal control l er hardware, and
component sensor current l oads. At the same ti me,
thi s system provi des i ncreased rel i abi l i ty, enhanced
di agnosti cs, and al l ows the addi ti on of many new fea-
ture capabi l i ti es.
The DDM ci rcui try control s the output to the
dri ver front door power l ock motor. The PDM ci r-
cui try control s the output to the power l ock motors
for the remai ni ng doors and the l i ftgate. When a door
l ock swi tch i s actuated, the door modul e ci rcui try for
that swi tch sends a message to the other door mod-
ul e on the CCD data bus to acti vate the output to the
remai ni ng power l ock motor(s).
8P - 2 POWER LOCK SYSTEMS ZG
Some of the features and functi ons of the power
l ock and Remote Keyl ess Entry (RKE) systems made
possi bl e because of the communi cati on of the door
modul es on the CCD data bus network i ncl ude:
A door-l ock i nhi bi t feature whi ch prevents the
power l ock system from bei ng energi zed wi th a door
swi tch i f the key i s i n the i gni ti on and/or the head-
l amps are on wi th the dri ver door open. However, the
l ocks can sti l l be operated manual l y wi th a key or
energi zed wi th the RKE transmi tter.
A rol l i ng door l ocks feature wi l l automati cal l y
l ock al l of the doors and the l i ftgate, after the vehi cl e
reaches a speed of about 24 ki l ometers-per-hour (15
mi l es-per-hour) or greater. Thi s feature wi l l al so l ock
the doors i f a door i s opened, then cl osed agai n at
any speed above 24 ki l ometers-per-hour (15 mi l es-
per-hour). Rol l i ng door l ocks i s a programmabl e fea-
ture of the power l ock system. Thi s feature can be
enabl ed or di sabl ed usi ng the DRB scan tool and the
An RKE system pani c mode, on model s so
equi pped. I f the Pani c button on the RKE transmi t-
ter i s depressed, the horn wi l l sound and l i ghts wi l l
fl ash on the vehi cl e for about three mi nutes, or unti l
any of the three transmi tter buttons i s depressed. A
vehi cl e speed of about 24 ki l ometers-per-hour (15
mi l es-per-hour) wi l l al so cancel the pani c mode.
A programmabl e feature of the RKE system i s
the enabl i ng or di sabl i ng of the horn chi rp fol l owi ng
the RKE Lock functi on. Thi s feature can be enabl ed
or di sabl ed usi ng the DRB scan tool and the proper
Another programmabl e feature i s the enabl i ng
or di sabl i ng of the RKE system unl ocki ng the dri ver
door onl y, or al l doors upon one depressi on of the
transmi tter Unl ock button. Thi s feature can be
enabl ed or di sabl ed usi ng the DRB scan tool and the
For di agnosi s of the DDM, PDM, or the CCD data
bus network, refer to the proper Body Di agnosti c
Procedures manual .
BODY CONTROL MODULE
supports and control s on model s so equi pped, i s the
Remote Keyl ess Entry (RKE) Pani c Mode. The BCM
recei ves i nput from the RKE recei ver i n the Passen-
ger Door Modul e (PDM) on the CCD data bus. The
programmi ng i n the BCM al l ows i t to process the
i nformati on from thi s i nput and send control outputs
to the headl amp rel ay, horn rel ay, and park l amp
rel ay to accompl i sh the pani c mode functi ons.
POWER LOCK MOTOR
I n the power l ock and Remote Keyl ess Entry
(RKE) systems, the l ocks are actuated by a reversi bl e
motor mounted wi thi n each door and the l i ftgate.
The dri ver front door l ock motor di recti on i s con-
trol l ed by the battery and ground feeds from the
Dri ver Door Modul e (DDM). The remai ni ng door l ock
motors and the l i ftgate l ock motor are control l ed by
the battery and ground feeds from the Passenger
Door Modul e (PDM).
The power l ock motor cannot be repai red and, i f
faul ty or damaged, the enti re motor must be
repl aced.
CIRCUIT BREAKER
An automati c resetti ng ci rcui t breaker i n the junc-
ti on bl ock i s used to protect the power l ock system
ci rcui t. The ci rcui t breaker can protect the system
from a short ci rcui t, or from an overl oad condi ti on
caused by an obstructed or stuck l ock motor, l atch, or
l ock l i nkage.
The ci rcui t breaker cannot be repai red and, i f
The Remote Keyl ess Entry (RKE) system transmi t-
ter i s equi pped wi th up to three buttons, l abel ed
Lock, Unl ock, and an opti onal Pani c button. I t i s al so
equi pped wi th a key ri ng and i s desi gned to serve as
a key fob. The operati ng range of the transmi tter
radi o si gnal i s up to 7 meters (23 feet) from the RKE
recei ver.
Each transmi tter has a di fferent vehi cl e access
code, whi ch must be programmed i nto the memory of
the RKE recei ver i n the vehi cl e i n order to operate
the RKE system. I n addi ti on, vehi cl es wi th the
opti onal memory system must have thei r access
codes programmed i n the RKE recei ver so that the
mol ded-i n numbers 1 or 2 on the back of the
transmi tter case coi nci de wi th the memory 1 and
2 buttons of the memory set swi tch i n the vehi cl e.
Transmi tter programmi ng must be performed wi th
a DRB scan tool . Refer to the proper Body Di agnosti c
Procedures manual for the transmi tter programmi ng
procedure.
The transmi tter operates on two Duracel l DL2016
(or equi val ent) batteri es. Typi cal battery l i fe i s from
one to two years. The transmi tter cannot be repai red
REMOTE KEYLESS ENTRY RECEIVER
The Remote Keyl ess Entry (RKE) recei ver i s a
radi o frequency uni t contai ned i n the Passenger Door
Modul e (PDM). The PDM al so contai ns the program
ci rcui try for the RKE system. The PDM i s l ocated
i nsi de the passenger si de front door, and i s secured
to the door tri m panel .
The RKE recei ver i s energi zed by one of up to
three messages from the RKE transmi tter; Unl ock,
Lock, or an opti onal Pani c. The PDM ci rcui try
responds to these messages to l ock or unl ock the
power l ock motors that i t control s. The PDM ci rcui try
al so puts Lock, Unl ock, and the opti onal Pani c mes-
sages on the Chrysl er Col l i si on Detecti on (CCD) data
bus.
These messages wi l l resul t i n the Dri ver Door
Modul e (DDM) l ocki ng or unl ocki ng the dri ver si de
front door, and/or the Body Control Modul e (BCM)
i ni ti ati ng the proper Horn Chi rp, I l l umi nated Entry,
and Vehi cl e Theft Al arm functi ons. I f the vehi cl e i s
equi pped wi th the opti onal memory system, the
proper CCD Unl ock message wi l l al so resul t i n the
DDM i ni ti ati ng i ts memory recal l functi ons.
For di agnosi s of the RKE recei ver, the PDM, the
DDM, or the CCD data bus, refer to the proper Body
Di agnosti c Procedures manual . The RKE recei ver i s
onl y servi ced as a uni t wi th the PDM and, i f faul ty
or damaged, the PDM uni t must be repl aced.
POWER LOCK AND REMOTE KEYLESS ENTRY
SYSTEM
As a prel i mi nary di agnosi s for the power l ock and
remote keyl ess entry systems, note the system oper-
ati on whi l e you actuate both the Lock and Unl ock
functi ons wi th the power l ock swi tches and the
remote keyl ess entry transmi tter. Then, proceed as
fol l ows:
I f the system fai l s to functi on wi th ei ther the
swi tches or the transmi tter, see the Ci rcui t Breaker
I f the system functi ons wi th both swi tches, but
not wi th the transmi tter, see the Remote Keyl ess
Entry Transmi tter di agnosi s i n thi s group.
I f the system functi ons wi th the transmi tter, but
not wi th one or both swi tches, see the Door Modul e
I f one l ock motor fai l s to operate wi th the
swi tches or the transmi tter, see the Power Lock
Motor di agnosi s i n thi s group.
CIRCUIT BREAKER
8W-61 - Power Door Locks i n Group 8W - Wi ri ng
Di agrams.
(1) Locate the correct ci rcui t breaker i n the junc-
ti on bl ock. Pul l out the ci rcui t breaker sl i ghtl y, but
be sure that the termi nal s sti l l contact the termi nal s
(2) Connect the negati ve l ead of a 12-vol t DC vol t-
meter to a good ground.
(3) Wi th the vol tmeter posi ti ve l ead, check both
termi nal s of the ci rcui t breaker for battery vol tage.
I f onl y one termi nal has battery vol tage, the ci rcui t
breaker i s faul ty and must be repl aced. I f nei ther ter-
mi nal has battery vol tage, repai r the open ci rcui t
from the Power Di stri buti on Center (PDC) as
requi red. I f the ci rcui t breaker checks OK, but no
power l ocks operate, see the di agnosi s for the Door
Modul e i n thi s group.
DOOR MODULE
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this component. The most
reliable, efficient, and accurate means to diagnose
this system involves the use of a DRB scan tool
and the proper Body Diagnostic Procedures man-
ual.
Remember, the DDM ci rcui try control s the output
to the dri ver si de front door power l ock motor. The
PDM ci rcui try control s the output to the power l ock
motors for the remai ni ng doors and the l i ftgate. For
Power Door Locks i n Group 8W - Wi ri ng Di agrams.
cabl e. Remove the front door tri m panel as descri bed
i n thi s group. Go to Step 2.
(2) Check the 12-way door modul e wi re harness
connector to see that i t i s ful l y seated i n the door
modul e receptacl e. I f OK, go to Step 3. I f not OK,
i nstal l the wi re harness connector properl y.
(3) Unpl ug the 12-way door modul e wi re harness
connector from the door modul e. Check for conti nui ty
between the ground ci rcui t cavi ty of the door modul e
12-way door modul e wi re harness connector. I f OK,
go to Step 5. I f not OK, repai r the open ci rcui t as
requi red.
cabl e. Check for conti nui ty between the door l ock
dri ver ci rcui t cavi ty of the 12-way door modul e wi re
harness connector and a good ground. Repeat the
check for the door unl ock dri ver ci rcui t cavi ty of the
door modul e wi re harness connector. I n each case
there shoul d be no conti nui ty. I f OK, go to Step 6. I f
(6) Pl ug the 12-way door modul e wi re harness con-
nector back i nto the door modul e. Unpl ug the i noper-
ati ve power l ock motor wi re harness connector.
Connect the battery negati ve cabl e. Go to Step 7.
(7) Connect the probes of a reversi bl e DC di gi tal
vol tmeter to the body wi re harness hal f of the power
l ock motor wi re harness connector. Observe the vol t-
meter whi l e actuati ng the power l ock swi tch i n the
l ock and unl ock di recti ons. There shoul d be a short
12-vol t vol tage spi ke as the swi tch i s moved to both
the l ock and unl ock posi ti ons, and no vol tage i n the
neutral posi ti on. I f OK, see the di agnosi s for Power
Lock Motor i n thi s group. I f not OK, repl ace the
faul ty door modul e.
POWER LOCK MOTOR
to the dri ver si de front door power l ock motor. The
PDM ci rcui try control s the output to the power l ock
motors for the remai ni ng doors and the l i ftgate. For
Power Door Locks i n Group 8W - Wi ri ng Di agrams.
(1) I f onl y one l ock motor i s i noperati ve, go to Step
2. I f al l l ock motors except the dri ver si de front door
are i noperati ve, the probl em may be caused by one
shorted motor. Unpl uggi ng a shorted motor from the
power l ock ci rcui t wi l l al l ow the good motors to oper-
ate. Unpl ug each PDM-control l ed l ock motor wi re
harness connector, one at a ti me, and recheck both
the l ock and unl ock functi ons by operati ng the power
l ock swi tch. I f unpl uggi ng one motor causes the other
motors to become functi onal , go to Step 2 to test the
unpl ugged motor.
(2) Once i t i s determi ned whi ch l ock motor i s i nop-
erati ve, that motor can be tested as fol l ows. Unpl ug
the wi re harness connector at the i noperati ve motor.
Appl y 12 vol ts to the motor termi nal s to check i ts
operati on i n one di recti on. Reverse the pol ari ty to
check the operati on i n the other di recti on. I f OK,
repai r the short or open ci rcui ts to the door modul e
as requi red. I f not OK, repl ace the faul ty l ock motor.
(1) Repl ace the Remote Keyl ess Entry (RKE)
transmi tter batteri es as descri bed i n thi s group. Test
each of the transmi tter functi ons. I f OK, di scard the
faul ty batteri es. I f not OK, go to Step 2.
(2) Perform the Remote Keyl ess Entry Transmi tter
Programmi ng procedure wi th the suspect transmi tter
and another known good transmi tter usi ng a DRB
scan tool , as descri bed i n the proper Di agnosti c Pro-
cedures manual .
(3) Test the RKE system operati on wi th both
transmi tters. I f both transmi tters fai l to operate the
power l ock system, use a DRB scan tool and the
proper Di agnosti c Procedures manual for di agnosi s of
the RKE system. I f the known good transmi tter oper-
ates the power l ocks and the suspect transmi tter
does not, repl ace the faul ty transmi tter.
NOTE: Be certain to perform the Remote Keyless
Entry Transmitter Programming procedure again
following this test. This procedure will erase the
access code of the test transmitter from the RKE
receiver.
POWER LIFTGLASS RELEASE SYSTEM
8W-61 - Power Door Locks i n Group 8W - Wi ri ng
Di agrams.
juncti on bl ock. I f OK, go to Step 3. I f not OK, repai r
(3) Unpl ug the l i ftgl ass l i mi t swi tch wi re harness
connector. Check for battery vol tage at the fused B(+)
ci rcui t cavi ty of the l i mi t swi tch wi re harness connec-
(4) Check for conti nui ty between the two termi nal s
of the l i ftgl ass l i mi t swi tch. There shoul d be conti nu-
i ty wi th the l i ftgate l atch unl ocked, and no conti nui ty
wi th the l atch l ocked. I f OK, go to Step 5. I f not OK,
repl ace the faul ty l i mi t swi tch.
(5) Unpl ug the l i ftgl ass push button swi tch wi re
harness connector. Wi th the l i ftgate l atch unl ocked,
check for battery vol tage at the l i ftgl ass l i mi t swi tch
output ci rcui t cavi ty of the swi tch wi re harness con-
nector. I f OK, go to Step 6. I f not OK, repai r the open
(6) Check for conti nui ty between the two termi nal s
of the l i ftgl ass push button swi tch. There shoul d be
no conti nui ty. Depress the swi tch, there shoul d now
be conti nui ty. I f OK, go to Step 7. I f not OK, repl ace
the faul ty push button swi tch.
(7) Unpl ug the l i ftgl ass rel ease sol enoi d wi re har-
ness connector. Check for conti nui ty between the
ground ci rcui t cavi ty of the wi re harness connector
and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 8. I f not OK, repai r the open ci rcui t
as requi red.
(8) Wi th the l i ftgate l atch unl ocked and the l i ft-
gl ass push button swi tch depressed, check for battery
vol tage at the l i ftgl ass push button output ci rcui t
cavi ty of the l i ftgl ass rel ease sol enoi d wi re harness
connector. I f OK, repl ace the faul ty sol enoi d. I f not
SERVICE PROCEDURES
BATTERY REPLACEMENT
To repl ace the Remote Keyl ess Entry (RKE) trans-
mi tter batteri es, separate the transmi tter case hal ves
at the center seam by pryi ng gentl y wi th a tri m
sti ck, or other sui tabl e wi de, fl at-bl aded tool . The
case snaps open and shut.
Repl ace the two batteri es wi th new Duracel l
DL2016, or thei r equi val ent. Be certai n that the bat-
teri es are i nstal l ed wi th thei r pol ari ty correctl y ori -
ented. Then, al i gn the two transmi tter case hal ves
wi th each other, and squeeze them fi rml y together
unti l they snap back i nto pl ace.
PROGRAMMING
To program the Remote Keyl ess Entry (RKE)
transmi tter access codes i nto the RKE recei ver i n the
passenger door modul e requi res the use of a DRB
scan tool . Refer to the proper Body Di agnosti c Proce-
dures manual for more i nformati on.
DOOR MODULE
cabl e.
(3) Remove the door tri m panel mounti ng screw
l ocated i n the bezel openi ng near the i nsi de door
l atch rel ease handl e (Fi g. 1).
speaker gri l l e.
sti ck, pry the tri m panel away from the door around
the peri meter and remove the tri m panel .
door modul e and the door courtesy l amp, i f equi pped.
(9) Remove the fi ve screws that secure the door
modul e to the door tri m panel (Fi g. 2).
(10) Remove the door modul e from the tri m panel .
U-NUT
FRONT DOOR
U-NUT
Fig. 2 Door Module Remove/Install
POWER MIRROR CONNECTOR DOOR MODULE 12WAY CON- NECTOR MOUNTINGSCREWS MEMORY SWITCH CONNECTOR
NOTE: If a new door module is installed, the pro-
grammable features must be enabled and/or dis-
POWER LOCK MOTOR
FRONT DOOR
(1) Remove the front door tri m panel as descri bed
under Door Modul e i n thi s group.
(2) Pul l back the watershi el d from the rear access
hol es of the i nner door panel .
(3) Remove the screws that secure the power l ock
motor and l atch assembl y to the door (Fi g. 3).
(4) Di sconnect al l of the l atch l i nkage rods from
the door l atch (Fi g. 4).
(5) Pul l the power l ock motor and l atch out from
the door far enough to unpl ug the wi re harness con-
nector.
(6) Remove the power l ock motor and l atch assem-
bl y from the door.
Ti ghten the power l ock motor and l atch screws to 10
Nm (95 i n. l bs.).
REAR DOOR
cabl e.
door power wi ndow swi tch.
(7) Pul l back the watershi el d from the rear access
hol es of the i nner door panel .
(8) Remove the screws that secure the power l ock
motor and l atch assembl y to the door (Fi g. 6).
(9) Di sconnect al l of the l atch l i nkage rods from
the door l atch.
(10) Pul l the power l ock motor and l atch out from
the door far enough to unpl ug the wi re harness con-
nector.
(11) Remove the power l ock motor and l atch
assembl y from the door.
Fig. 3 Door Latch Remove/Install
ACCESS HOLE DOOR
LATCH MOUNTING
BOLTS
LATCH
Fig. 4 Door Latch
OUTSIDE HAN- DLE LATCH ROD INSIDE RELEASE LATCH ROD INSIDE LOCK ROD LOCK SOLE- NOID LOCK LATCHROD
Ti ghten the power l ock motor and l atch screws to 10
Nm (95 i n. l bs.).
LIFTGATE
cabl e.
(2) Remove the screws that secure the l i ftgate
l ower tri m panel to the l i ftgate (Fi g. 7).
sti ck, pry the tri m panel away from the l i ftgate
around the peri meter and remove the tri m panel .
(4) Di sconnect the l ock actuator motor l i nkage cl i p
at the l i ftgate l atch handl e (Fi g. 8).
(5) Remove the two screws that secure the l ock
actuator motor to the l i ftgate (Fi g. 9).
actuator motor.
(7) Remove the motor from the l i ftgate.
Ti ghten the actuator motor mounti ng screws to 3
Nm (28 i n. l bs.).
Fig. 6 Door Latch Remove/Install - Typical
LATCH SCREWS LATCH ADJUST- MENT SCREW
Fig. 7 Liftgate Trim Panel Remove/Install
UPPER TRIM PANEL LIFTGATE LOWER TRIMPANEL
Fig. 8 Lock Actuator Motor Linkage Remove/Install
LOCK ACTUATOR LINKAGE CLIP LIFTGATE DISARM SWITCH LIFTGATE LOCK ROD
Fig. 9 Liftgate Lock Motor Remove/Install
POWER LOCK ACTUA- TOR LOCK ROD HANDLE LATCH ROD LATCH
VEHICLE THEFT/SECURITY SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
ARMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DISARMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENABLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER-UP MODE . . . . . . . . . . . . . . . . . . . . . . 3
TAMPER ALERT . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUTO HEADLAMP RELAY . . . . . . . . . . . . . . . . . 4
DOOR AJAR SWITCH . . . . . . . . . . . . . . . . . . . . 4
DOOR LOCK CYLINDER SWITCH . . . . . . . . . . . 4
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LIFTGATE AJAR SWITCH . . . . . . . . . . . . . . . . . 4
LIFTGATE LOCK CYLINDER SWITCH . . . . . . . . 4
LIFTGLASS AJAR SWITCH . . . . . . . . . . . . . . . . 4
PARK LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . 4
SET LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VEHICLE THEFT SECURITY SYSTEM OR
VEHICLE IMMOBILIZER SYSTEM . . . . . . . . . . 5
AUTO HEADLAMP AND PARK LAMP RELAYS . . 8
DOOR AJAR SWITCH . . . . . . . . . . . . . . . . . . . . 5
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SET LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
INTRODUCTION
The Vehi cl e Theft Securi ty System (VTSS) i s an
avai l abl e factory-i nstal l ed opti on on versi ons of thi s
model bui l t for sal e i n North Ameri ca. Thi s system i s
desi gned to provi de peri meter protecti on agai nst
unauthori zed use or tamperi ng by moni tori ng the
vehi cl e doors, l i ftgate, and i gni ti on system. I f unau-
thori zed use or tamperi ng i s detected, the system
responds by soundi ng the horn, fl ashi ng the exteri or
l amps, and provi di ng an engi ne no-run feature. The
VTSS can be di sarmed by unl ocki ng the vehi cl e wi th
the key i n ei ther front door l ock cyl i nder or usi ng the
Remote Keyl ess Entry (RKE) transmi tters.
The vehi cl e i mmobi l i zer system i s factory-i nstal l ed
standard equi pment on model s bui l t for sal e outsi de
North Ameri ca. Model s equi pped wi th the vehi cl e
i mmobi l i zer system cannot be equi pped wi th the
VTSS. The vehi cl e i mmobi l i zer system i s desi gned to
provi de passi ve protecti on agai nst unauthori zed vehi -
cl e use by preventi ng the engi ne from operati ng
whi l e the system i s armed. The vehi cl e i mmobi l i zer
system can onl y be di sarmed usi ng the Remote Key-
l ess Entry (RKE) transmi tters.
Fol l owi ng are some general descri pti ons of the fea-
tures of the VTSS and the vehi cl e i mmobi l i zer sys-
tem. Refer to the vehi cl e owners manual for more
i nformati on on the use and operati on of these sys-
tems. Refer to Group 8P - Power Lock Systems for
more i nformati on on the RKE system recei ver and
transmi tters. Refer to 8W-39 - Vehi cl e Theft Securi ty
System i n Group 8W - Wi ri ng Di agrams for compl ete
ENABLING
VEHICLE THEFT SECURITY SYSTEM
The VTSS engi ne no-run feature i s di sabl ed when
i t i s shi pped from the factory. Thi s i s done by pro-
grammi ng wi thi n the Powertrai n Control Modul e
(PCM). The l ogi c i n the PCM prevents the VTSS
engi ne no-run feature from armi ng unti l the engi ne
start counter wi thi n the PCM sees twenty engi ne
starts. The VTSS no-run feature must be enabl ed
when the vehi cl e i s recei ved from the assembl y pl ant.
The preferred method for enabl i ng the VTSS
engi ne no-run feature i s to el ectroni cal l y advance the
PCM engi ne start counter usi ng a DRB scan tool .
Refer to the Vehi cl e Theft Securi ty System menu
ZG VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1
i tem on the DRB scan tool for the procedures. Once
thi s condi ti on has been met, the PCM wi l l al l ow the
engi ne no-run feature to arm.
Once the VTSS engi ne no-run feature has been
enabl ed, i t cannot be di sabl ed unl ess the PCM i s
repl aced wi th a new uni t. The same VTSS engi ne no-
run feature enabl e l ogi c wi l l appl y anyti me the PCM
i s repl aced wi th a new uni t.
VEHICLE IMMOBILIZER SYSTEM
The vehi cl e i mmobi l i zer system i s di sabl ed when i t
i s shi pped from the factory. Thi s i s done by program-
mi ng wi thi n the Powertrai n Control Modul e (PCM)
and the Body Control Modul e (BCM). The l ogi c i n the
BCM al l ows the vehi cl e i mmobi l i zer system functi ons
to remai n dormant i n vehi cl es sol d i n countri es
where i t i s not requi red. The l ogi c i n the PCM pre-
vents the i mmobi l i zer system from armi ng unti l the
engi ne start counter wi thi n the PCM sees twenty
engi ne starts. The vehi cl e i mmobi l i zer system must
be enabl ed when the vehi cl e i s recei ved from the
assembl y pl ant, i f thi s feature i s requi red or desi red.
The onl y method for setti ng up the BCM to al l ow
the i mmobi l i zer system to become functi onal i s to use
a DRB scan tool . Refer to the Body Computer menu
i tem on the DRB scan tool for the procedures. The
preferred method for enabl i ng the vehi cl e i mmobi -
l i zer system i s to el ectroni cal l y advance the PCM
engi ne start counter usi ng a DRB scan tool . Refer to
the Vehi cl e Theft Securi ty System menu i tem on the
DRB scan tool for the procedures. Once these condi -
ti ons have been met, the BCM and PCM wi l l al l ow
the vehi cl e i mmobi l i zer system to functi on and arm.
Once the vehi cl e i mmobi l i zer system has been
enabl ed, i t cannot be di sabl ed unl ess the PCM and
the BCM are repl aced wi th new uni ts. The same
vehi cl e i mmobi l i zer system enabl e l ogi c wi l l appl y
anyti me the PCM and/or the BCM are repl aced wi th
new uni ts.
ARMING
Passi ve armi ng of the VTSS occurs when the vehi -
cl e i s exi ted wi th the key removed from the i gni ti on
swi tch, the headl amps are turned off, and the doors
are l ocked usi ng the power l ock swi tch. The power
l ock swi tch wi l l not functi on i f the key i s i n the i gni -
ti on swi tch or the headl amps are on wi th the dri ver
si de front door open. The VTSS wi l l not arm i f ei ther
front door or the l i ftgate are l ocked usi ng the key i n
the l ock cyl i nder.
Acti ve armi ng of the VTSS occurs when the
Remote Keyl ess Entry (RKE) transmi tter i s used to
l ock the vehi cl e, even i f the doors and/or the l i ftgate
are open when the RKE transmi tter Lock button i s
depressed. However, the VTSS armi ng wi l l not be
compl ete unti l al l the doors and the l i ftgate are
cl osed.
Fol l owi ng successful passi ve or acti ve VTSS arm-
i ng, the VTSS set l amp on the top of the i nstrument
panel wi l l fl ash rapi dl y for about fi fteen seconds after
the i l l umi nated entry system ti mes out. Thi s i ndi -
cates that VTSS armi ng i s i n progress. Once the fi f-
teen second armi ng functi on i s compl ete, the set
l amp wi l l fl ash at a sl ower rate to i ndi cate that the
VTSS i s armed.
Acti ve armi ng of the vehi cl e i mmobi l i zer system
occurs when the vehi cl e i s l ocked usi ng the power
l ock swi tch or when the Lock button of the Remote
Keyl ess Entry (RKE) transmi tter i s used to l ock the
vehi cl e. Armi ng wi l l occur, even i f the doors and/or
the l i ftgate are open when the vehi cl e i s l ocked, as
l ong as the i gni ti on swi tch i s i n the Off posi ti on. The
vehi cl e i mmobi l i zer system cannot be acti vel y armed
whi l e the i gni ti on swi tch i s i n the On or Start posi -
ti ons.
Passi ve armi ng of the system occurs when the i gni -
ti on swi tch i s i n the Off posi ti on for more than fi ve
mi nutes (one mi nute for vehi cl es sol d i n the Uni ted
Ki ngdom). See Power-Up Mode i n thi s group for a
descri pti on of other condi ti ons that can resul t i n pas-
si ve armi ng of the vehi cl e i mmobi l i zer system.
Fol l owi ng recei pt of a passi ve or acti ve request for
armi ng of the vehi cl e i mmobi l i zer system, a set l amp
l ocated on top of the i nstrument panel wi l l begi n to
fl ash rapi dl y for fi fteen seconds. Fol l owi ng successful
vehi cl e i mmobi l i zer system armi ng (about fi fteen sec-
onds), the set l amp wi l l conti nue to fl ash, but at a
much sl ower rate. The sl ow fl ashi ng of the set l amp
wi l l conti nue for as l ong as the vehi cl e i mmobi l i zer
system i s armed.
DISARMING
Passi ve di sarmi ng of the VTSS occurs when the
vehi cl e i s unl ocked usi ng the key to unl ock ei ther
front door or the l i ftgate. Acti ve di sarmi ng of the
VTSS occurs when the vehi cl e i s unl ocked by
depressi ng the Unl ock button of the Remote Keyl ess
Entry (RKE) transmi tter.
Once the al arm has been acti vated (horn soundi ng,
l i ghts fl ashi ng, and the engi ne no-run feature), ei ther
di sarmi ng method wi l l al so deacti vate the al arm.
Depressi ng the Pani c button on the RKE transmi t-
ter wi l l al so di sarm the VTSS, but the horn wi l l
sound and the l i ghts wi l l fl ash for about three mi n-
utes as part of the Pani c feature. Refer to Group 8P -
Power Lock Systems for more i nformati on on the
Pani c feature.
8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS ZG
Acti ve di sarmi ng of the vehi cl e i mmobi l i zer system
occurs when the Unl ock button of ei ther of the two
Remote Keyl ess Entry (RKE) transmi tters i s
depressed, regardl ess of i gni ti on swi tch posi ti on. Thi s
i s the onl y way that the vehi cl e i mmobi l i zer system
can be di sarmed. Fol l owi ng successful di sarmi ng of
the vehi cl e i mmobi l i zer system, the set l amp on top
of the i nstrument panel wi l l stop fl ashi ng.
POWER-UP MODE
When the armed VTSS senses that the battery has
been di sconnected and reconnected, i t enters i ts pow-
er-up mode. I n the power-up mode the al arm system
remai ns armed fol l owi ng a battery fai l ure or di scon-
nect. I f the VTSS was armed pri or to a battery di s-
connect or fai l ure, the system wi l l have to be acti vel y
or passi vel y di sarmed after the battery i s recon-
nected.
The power-up mode wi l l al so appl y i f the battery
goes dead whi l e the system i s armed, and battery
jump-starti ng i s attempted. The engi ne no-run fea-
ture wi l l prevent the engi ne from starti ng unti l the
al arm system has been acti vel y or passi vel y di s-
armed.
When the vehi cl e i mmobi l i zer system senses that
the vehi cl e battery has been di sconnected and recon-
nected, i t enters i ts power-up mode. I f the i mmobi -
l i zer system was armed pri or to the battery
di sconnect, the system remai ns armed when the bat-
tery i s reconnected.
I f the i mmobi l i zer system was di sarmed pri or to
the battery di sconnect, the system wi l l remai n di s-
armed i f the battery i s reconnected wi thi n fi ve mi n-
utes (one mi nute for vehi cl es sol d i n the Uni ted
Ki ngdom). The system wi l l passi vel y arm i tsel f when
the battery i s reconnected more than fi ve mi nutes
(one mi nute for vehi cl es sol d i n the Uni ted Ki ngdom)
after a battery di sconnect or fai l ure. After any pas-
si ve armi ng, the system wi l l have to be acti vel y di s-
armed by depressi ng the Unl ock button on one of the
Remote Keyl ess Entry (RKE) transmi tters.
The power-up mode l ogi c al so appl i es i f the battery
goes dead, and battery jump-starti ng i s attempted.
The engi ne no-run feature wi l l prevent the engi ne
from operati ng unti l the vehi cl e i mmobi l i zer system
has been acti vel y di sarmed.
TAMPER ALERT
The VTSS tamper al ert wi l l sound the horn three
ti mes upon di sarmi ng, i f the al arm was acti vated and
has si nce ti med-out (about ei ghteen mi nutes). Thi s
feature al erts the dri ver that the VTSS was acti vated
whi l e the vehi cl e was unattended.
BODY CONTROL MODULE
functi ons and features on the vehi cl e. The BCM con-
tai ns a central processi ng uni t and i nterfaces wi th
other modul es i n the vehi cl e on the Chrysl er Col l i -
si on Detecti on (CCD) data bus network.
many new feature capabi l i ti es. Functi ons and fea-
tures that the BCM supports and control s i ncl ude the
Vehi cl e Theft Securi ty System (VTSS) and the vehi cl e
i mmobi l i zer system.
I n the VTSS, the BCM recei ves CCD message
i nputs from the Passenger Door Modul e, whi ch con-
tai ns the Remote Keyl ess Entry (RKE) recei ver. I n
addi ti on to the i nformati on recei ved over the CCD
data bus, the BCM recei ves hard-wi red i nputs from
the door ajar, door l ock cyl i nder, i gni ti on, l i ftgate
ajar, l i ftgate l ock cyl i nder, and l i ftgl ass ajar swi tches.
The programmi ng i n the BCM al l ows i t to process
the i nformati on from al l of these i nputs and send
control outputs to energi ze or de-energi ze the auto
headl amp rel ay, horn rel ay, park l amp rel ay, Power-
trai n Control Modul e (PCM), and the set l amp.
I n the vehi cl e i mmobi l i zer system, the BCM
recei ves CCD message i nputs from the Passenger
Door Modul e, whi ch contai ns the Remote Keyl ess
Entry (RKE) recei ver. I n addi ti on to the i nformati on
recei ved over the CCD data bus, the BCM recei ves a
hard-wi red i nput from the i gni ti on swi tch. The pro-
grammi ng i n the BCM al l ows i t to process the i nfor-
mati on from these i nputs and send the proper
outputs to the Powertrai n Control Modul e (PCM) and
the set l amp.
DOOR AJAR SWITCH
The door ajar swi tches are mounted to the pi l l ar i n
the rear of each door openi ng. They are pl unger-type
swi tches that are case grounded to the pi l l ar. When
the door i s open the swi tch i s cl osed, and when the
door i s cl osed the swi tch i s open.
The door ajar swi tches cannot be repai red and, i f
DOOR LOCK CYLINDER SWITCH
The door l ock cyl i nder swi tches are mounted to the
back of the key l ock cyl i nder i nsi de each front door.
They are normal l y-open momentary swi tches that
cl ose to ground onl y when the l ock cyl i nder i s rotated
to the unl ock posi ti on.
The door l ock cyl i nder swi tches cannot be repai red
LIFTGATE AJAR SWITCH
The l i ftgate ajar swi tch i s i ntegral to the l i ftgate
l atch assembl y on the l i ftgate. I t i s a momentary-
type swi tch that i s open when the l i ftgate i s cl osed,
and cl osed when the l i ftgate i s open.
The l i ftgate ajar swi tch cannot be repai red and, i f
faul ty or damaged, the l i ftgate l atch assembl y must
be repl aced.
LIFTGATE LOCK CYLINDER SWITCH
The l i ftgate l ock cyl i nder swi tch i s mounted to the
back of the key l ock cyl i nder i nsi de the l i ftgate. I t i s
a normal l y-open momentary swi tch that cl oses to
ground onl y when the l ock cyl i nder i s rotated to the
unl ock posi ti on.
The l i ftgate l ock cyl i nder swi tch cannot be repai red
LIFTGLASS AJAR SWITCH
The l i ftgl ass ajar swi tch i s i ntegral to the l i ftgl ass
type swi tch that i s open when the l i ftgl ass i s cl osed,
and cl osed when the l i ftgl ass i s open.
The l i ftgl ass ajar swi tch cannot be repai red and, i f
faul ty or damaged, the l i ftgl ass l atch assembl y must
be repl aced.
AUTO HEADLAMP RELAY
The auto headl amp rel ay i s a I nternati onal Stan-
dards Organi zati on (I SO) mi cro-rel ay. The termi nal
desi gnati ons and functi ons are the same as a conven-
ti onal I SO rel ay. However, the mi cro-rel ay termi nal
ori entati on (or footpri nt) i s di fferent, current capaci ty
i s l ower, and the rel ay case di mensi ons are smal l er
The auto headl amp rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the head-
l amps when the Body Control Modul e (BCM) grounds
the rel ay coi l . 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 auto headl amp rel ay.
The auto headl amp rel ay i s l ocated i n the juncti on
bl ock, on the ri ght cowl si de panel bel ow the i nstru-
ment panel i n the passenger compartment.
The auto headl amp rel ay cannot be repai red and, i f
HORN RELAY
swi tches battery current to the horns when the horn
swi tch or the Body Control Modul e (BCM) grounds
the horn rel ay.
removi ng the horn rel ay from PDC unti l further
PARK LAMP RELAY
The park l amp rel ay i s a I nternati onal Standards
ti on (or footpri nt) i s di fferent, current capaci ty i s
The park l amp rel ay i s a el ectromechani cal devi ce
that swi tches battery current to the park l amps
when the Body Control Modul e grounds the rel ay
coi l . See the Di agnosi s and Testi ng secti on of thi s
group for more i nbformati on on the operati on of the
park l amp rel ay.
The park l amp rel ay i s l ocated i n the juncti on
ment panel i n the passenger compartment. The park
l amp rel ay can be accessed by removi ng the fuse
access panel and the ri ght cowl si de tri m panel .
The park l amp rel ay cannot be repai red and, i f
SET LAMP
The set l amp i s a red l i ght-emi tti ng di ode mounted
wi th the auto headl amp ambi ent l i ght sensor on top
of the i nstrument panel near the dri ver si de defroster
outl et. The set l amp recei ves fused battery feed at al l
ti mes and i s grounded by the Body Control Modul e to
gi ve a vi si bl e i ndi cati on of the Vehi cl e Theft Securi ty
System or vehi cl e i mmobi l i zer system status.
The set l amp cannot be repai red and, i f damaged
or faul ty, the set l amp/auto headl amp ambi ent l i ght
sensor must be repl aced as a uni t.
VEHICLE THEFT SECURITY SYSTEM OR VEHICLE
IMMOBILIZER SYSTEM
INJURY.
The Vehi cl e Theft Securi ty System (VTSS) or the
vehi cl e i mmobi l i zer system and the data bus network
shoul d be di agnosed usi ng the DRB scan tool and the
proper Body Di agnosti c Procedures manual . The
DRB wi l l provi de confi rmati on that the bus i s func-
ti onal , that the Body Control Modul e (BCM) i s
recei vi ng and sendi ng the proper messages on the
bus, that the BCM i s recei vi ng the proper hard-wi red
i nputs and sendi ng the proper hard-wi red outputs,
and that the Powertrai n Control Modul e i s recei vi ng
the bus messages from the BCM. Refer to the Vehi cl e
Theft Securi ty System menu i tem on the DRB scan
tool for the procedures. Refer to 8W-39 - Vehi cl e
Theft Securi ty System i n Group 8W - Wi ri ng Di a-
RELAYS
Center (PDC) i n the engi ne compartment. The auto
headl amp and park l amp rel ays are l ocated i n the
juncti on bl ock i n the passenger compartment. Each
of these rel ays can be tested as descri bed i n the fol -
l owi ng procedure, however the ci rcui ts they are used
i n do vary. To test the rel ay ci rcui ts, refer to the ci r-
cui t descri pti ons and di agrams i n 8W-39 - Vehi cl e
grams.
INJURY.
Remove the rel ay from the PDC or juncti on bl ock
tests:
and 30. I f OK, test the rel ay ci rcui ts. I f not OK,
repl ace the faul ty rel ay.
DOOR AJAR SWITCH
cabl e.
(2) Remove the screw that secures the door ajar
swi tch to the pi l l ar at the rear of the door openi ng
(Fi g. 1).
(3) Pul l the swi tch from the mounti ng hol e i n the
door openi ng far enough to access the wi re harness
connector.
swi tch.
Relay Terminals
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
Ti ghten the swi tch mounti ng screw to 1.7 Nm (15 i n.
l bs.).
cabl e.
door modul e and set the tri m panel asi de.
(8) Pul l the watershi el d away from the rear access
hol es i n the i nner door panel .
(9) Remove the U-cl i p retai ner that secures the
l ock cyl i nder to the outer door panel (Fi g. 3).
(10) Di sconnect the l ock cyl i nder rod from the door
l atch by unsnappi ng the retai ner from the rod.
(11) Pul l the l ock cyl i nder out from the outer door
panel far enough to pry the l ock cyl i nder swi tch off of
the back of the l ock cyl i nder (Fi g. 4).
(12) Unpl ug the l ock cyl i nder swi tch wi re harness
connector and remove the swi tch from i nsi de the
door.
cabl e.
(4) Remove the three screws that secure the l i ft-
gate l atch to the l i ftgate (Fi g. 6).
(5) Di sconnect the l i ftgate handl e l atch actuator
rod from the l atch.
(6) Unpl ug the l i ftgate ajar swi tch wi re harness
connector from the l atch.
(7) Remove the l atch from the l i ftgate.
Fig. 1 Door Ajar Switch Remove/Install
REAR DOOR AJAR SWITCH SCREW FRONT DOOR AJAR SWITCH SCREW FWD
Fig. 3 Door Lock Cylinder Remove/Install
OUTSIDE DOOR HAN- DLE LOCK CYLINDERU-CLIP LINKAGE CLIP
Ti ghten the l atch mounti ng screws to 7 Nm (62 i n
l bs.).
cabl e.
(4) Pry the l i ftgate l ock cyl i nder swi tch off of the
back of the l ock cyl i nder (Fi g. 8).
connector and remove the swi tch from i nsi de the l i ft-
gate.
cabl e.
Fig. 4 Door Lock Cylinder Switch Remove/Install-
Typical
DOOR DIS- ARM SWITCH LOCK CYLIN- DER
Fig. 6 Liftgate Latch/Lock Components
LOCK RETAIN- ING CLIP HANDLE POWER LOCK ACTUATOR
LOCK ROD
HANDLE HANDLE LATCH ROD LATCH LOCK
(4) Remove the two nuts that secure the l i ftgl ass
l atch to the l i ftgate i nner panel (Fi g. 10).
(5) Unpl ug the wi re harness connectors for the l i ft-
gl ass l atch sol enoi d and the l i ftgl ass ajar swi tch.
(6) Remove the l i ftgl ass l atch from the l i ftgate.
Ti ghten the l atch mounti ng nuts to 11 Nm (100 i n.
l bs.).
AUTO HEADLAMP AND PARK LAMP RELAYS
INJURY.
cabl e.
cowl si de tri m to the ri ght front door openi ng tri m.
Fig. 8 Liftgate Lock Cylinder Switch Remove/Install
LOCK ACTUATOR LINKAGE CLIP LIFTGATE DISARM SWITCH LIFTGATE LOCK ROD
Fig. 10 Liftglass Ajar Switch Remove/Install
LATCH AND SWITCH NUT FWD REINFORCE- MENT REAR WIPER MOTOR
Fig. 11 Right Cowl Side Trim Remove/Install
(6) Unpl ug the headl amp or park l amp rel ay from
the juncti on bl ock.
(7) I nstal l the headl amp or park l amp rel ay by
al i gni ng the rel ay termi nal s wi th the cavi ti es i n the
juncti on bl ock and pushi ng the rel ay fi rml y i nto
pl ace.
(10) I nstal l the ri ght cowl si de tri m and the fuse
access panel .
HORN RELAY
cabl e.
SET LAMP
INJURY.
cabl e.
sti ck, pry the cowl top tri m panel off of the i nstru-
ment panel top pad (Fi g. 13).
far enough to unpl ug the wi re harness connector
from the sol ar sensor, or to remove the sol ar sensor
from the cowl top tri m between the passenger si de
and center defroster outl ets.
cl e.
(5) Remove the auto headl amp l i ght sensor/vehi cl e
theft securi ty system set l amp mounti ng screw near
the dri ver si de defroster duct outl et.
(6) Pul l the l amp up far enough to unpl ug the wi re
harness connector and remove the l amp.
POSITIVECABLE NEGATIVE CABLE POWER DISTRIBU- TION CENTER OILED FELT WASHER FWD
VEHICLE THEFT/SECURITY SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
ARMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DISARMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER-UP MODE . . . . . . . . . . . . . . . . . . . . . . 2
TAMPER ALERT . . . . . . . . . . . . . . . . . . . . . . . . . 2
AUTO HEADLAMP RELAY . . . . . . . . . . . . . . . . . 3
DOOR AJAR SWITCH . . . . . . . . . . . . . . . . . . . . 2
HOOD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IMMOBILIZER RECEIVER . . . . . . . . . . . . . . . . . 4
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . . 3
IMMOBILIZER TRANSMITTER . . . . . . . . . . . . . . 4
PARK LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . 3
POWER-UP MODE . . . . . . . . . . . . . . . . . . . . . . 5
SET LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VEHICLE THEFT SECURITY SYSTEM . . . . . . . . 5
SERVICE PROCEDURES
ENABLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VEHICLE IMMOBILIZER SYSTEM . . . . . . . . . . . 6
AUTO HEADLAMP AND PARK LAMP RELAYS . 10
DOOR AJAR SWITCH . . . . . . . . . . . . . . . . . . . . 7
HOOD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 7
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IMMOBILIZER RECEIVER . . . . . . . . . . . . . . . . . 7
LIFTGLASS AJAR SWITCH . . . . . . . . . . . . . . . 10
SET LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL INFORMATION
INTRODUCTION
The Vehi cl e Theft Securi ty System (VTSS) i s an
avai l abl e factory-i nstal l ed opti on on thi s model . Thi s
system i s desi gned to provi de peri meter protecti on
agai nst unauthori zed use or tamperi ng by moni tori ng
the vehi cl e doors, hood, l i ftgate, and i gni ti on system.
I f unauthori zed use or tamperi ng i s detected, the sys-
tem responds by soundi ng the horn, fl ashi ng the
exteri or l amps, and provi di ng an engi ne no-run fea-
ture.
Fol l owi ng are some general descri pti ons of the fea-
tures of the VTSS. Refer to the vehi cl e owners man-
ual for addi ti onal i nformati on. Refer to 8W-39 -
Vehi cl e Theft Securi ty System i n Group 8W - Wi ri ng
grams.
ARMING
Passi ve armi ng of the VTSS occurs when the vehi -
cl e i s exi ted wi th the key removed from the i gni ti on
swi tch, the headl amps are turned off, and the doors
are l ocked usi ng the power l ock swi tch. The power
l ock swi tch wi l l not functi on i f the key i s i n the i gni -
ti on swi tch or the headl amps are on wi th the dri vers
door open. The VTSS wi l l not arm i f ei ther front door
or the l i ftgate are l ocked usi ng the key i n the l ock
cyl i nder.
Acti ve armi ng of the VTSS occurs when the
Remote Keyl ess Entry (RKE) transmi tter i s used to
l ock the vehi cl e, even i f the doors and/or the l i ftgate
are open when the RKE transmi tter Lock button i s
depressed. However, the VTSS armi ng wi l l not be
compl ete unti l al l the doors and the l i ftgate are
cl osed.
Fol l owi ng successful passi ve or acti ve VTSS arm-
i ng, the VTSS set l amp on the top of the i nstrument
panel wi l l fl ash rapi dl y for about 15 seconds after the
i l l umi nated entry system ti mes out. Thi s i ndi cates
that VTSS armi ng i s i n progress. I f the l i ght stays on
steadi l y duri ng the armi ng, i t i ndi cates that the hood
swi tch i s cl osed (the hood i s open). The VTSS wi l l
sti l l arm i f the hood i s open, but the engi ne compart-
ment wi l l not be protected. Once the 15 second arm-
i ng functi on i s compl ete, the set l amp wi l l fl ash at a
sl ower rate to i ndi cate that the VTSS i s armed.
DISARMING
Passi ve di sarmi ng of the VTSS occurs when the
vehi cl e i s unl ocked usi ng the key to unl ock ei ther
front door or the l i ftgate. Acti ve di sarmi ng of the
VTSS occurs when the vehi cl e i s unl ocked by
depressi ng the Unl ock button of the RKE transmi t-
ter.
Once the al arm has been acti vated (horn soundi ng,
l i ghts fl ashi ng, and the engi ne no-run feature), ei ther
di sarmi ng method wi l l al so deacti vate the al arm.
Depressi ng the Pani c button on the RKE transmi t-
ter wi l l al so di sarm the VTSS, but the horn wi l l
sound and the l i ghts wi l l fl ash for about three mi n-
utes as part of the Pani c feature. Refer to Group 8P -
Power Lock Systems for more i nformati on on the
Pani c feature.
POWER-UP MODE
When the armed VTSS senses that the battery has
been di sconnected and reconnected, i t enters i ts pow-
er-up mode. I n the power-up mode the al arm system
remai ns armed fol l owi ng a battery fai l ure or di scon-
nect. I f the VTSS was armed pri or to a battery di s-
connect or fai l ure, the system wi l l have to be acti vel y
or passi vel y di sarmed fol l owi ng a battery reconnec-
ti on.
The power-up mode wi l l al so appl y i f the battery
goes dead whi l e the system i s armed, and battery
jump-starti ng i s attempted. The engi ne no-run fea-
ture wi l l prevent the engi ne from starti ng unti l the
al arm system has been acti vel y or passi vel y di s-
armed.
TAMPER ALERT
The VTSS tamper al ert wi l l sound the horn three
ti mes upon di sarmi ng, i f the al arm was acti vated and
has si nce ti med-out (about ei ghteen mi nutes). Thi s
feature al erts the dri ver that the VTSS was acti vated
whi l e the vehi cl e was unattended.
BODY CONTROL MODULE
supports and control s, i s the Vehi cl e Theft Securi ty
System (VTSS). I n addi ti on to the i nformati on
recei ved on the CCD data bus, the BCM recei ves
hard-wi red i nputs from the door ajar, door l ock cyl i n-
der, hood, l i ftgate ajar, l i ftgate l ock cyl i nder, and l i ft-
gl ass ajar swi tches. I n i ts rol e as the VTSS control l er,
the programmi ng i n the BCM al l ows i t to process the
i nformati on from al l of i ts i nputs and send control
outputs to energi ze or de-energi ze the auto headl amp
rel ay, horn rel ay, park l amp rel ay, Powertrai n Con-
trol Modul e (PCM), and the securi ty set l amp.
HOOD SWITCH
The hood swi tch i s mounted to the ri ght i nner
fender l edge, under the hood and near the battery. I t
i s a pl unger-type swi tch that i s case grounded to the
fender shi el d. When the hood i s open the swi tch i s
cl osed, and when the hood i s cl osed the swi tch i s
open.
The hood swi tch cannot be repai red and, i f faul ty
DOOR AJAR SWITCH
The door ajar swi tches are mounted to the pi l l ar i n
the rear of each door openi ng. They are pl unger-type
swi tches that are case grounded to the pi l l ar. When
the door i s open the swi tch i s cl osed, and when the
door i s cl osed the swi tch i s open.
The door ajar swi tches cannot be repai red and, i f
The door l ock cyl i nder swi tches are mounted to the
back of the key l ock cyl i nder i nsi de each front door.
They are normal l y-open momentary swi tches that
cl ose to ground onl y when the l ock cyl i nder i s rotated
to the unl ock posi ti on.
The door l ock cyl i nder swi tches cannot be repai red
The l i ftgate ajar swi tch i s i ntegral to the l i ftgate
type swi tch that i s open when the l i ftgate i s cl osed,
and cl osed when the l i ftgate i s open.
The l i ftgate ajar swi tch cannot be repai red and, i f
faul ty or damaged, the l i ftgate l atch assembl y must
be repl aced.
The l i ftgate l ock cyl i nder swi tch i s mounted to the
back of the key l ock cyl i nder i nsi de the l i ftgate. I t i s
a normal l y-open momentary swi tch that cl oses to
ground onl y when the l ock cyl i nder i s rotated to the
unl ock posi ti on.
The l i ftgate l ock cyl i nder swi tch cannot be repai red
The l i ftgl ass ajar swi tch i s i ntegral to the l i ftgl ass
type swi tch that i s open when the l i ftgl ass i s cl osed,
and cl osed when the l i ftgl ass i s open.
The l i ftgl ass ajar swi tch cannot be repai red and, i f
faul ty or damaged, the l i ftgl ass l atch assembl y must
be repl aced.
AUTO HEADLAMP RELAY
The auto headl amp rel ay i s a I nternati onal Stan-
dards Organi zati on (I SO) mi cro-rel ay. The termi nal
desi gnati ons and functi ons are the same as a conven-
ti onal I SO rel ay. However, the mi cro-rel ay termi nal
ori entati on (or footpri nt) i s di fferent, current capaci ty
i s l ower, and the rel ay case di mensi ons are smal l er
The auto headl amp rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the head-
l amps when the Body Control Modul e (BCM) grounds
the auto headl amp rel ay.
The auto headl amp rel ay i s l ocated i n the juncti on
ment panel i n the passenger compartment.
The auto headl amp rel ay cannot be repai red and, i f
HORN RELAY
swi tches battery current to the horns when the horn
swi tch or the Body Control Modul e (BCM) grounds
the horn rel ay.
removi ng the horn rel ay from PDC unti l further
PARK LAMP RELAY
The park l amp rel ay i s a I nternati onal Standards
ti on (or footpri nt) i s di fferent, current capaci ty i s
The park l amp rel ay i s a el ectromechani cal devi ce
that swi tches battery current to the park l amps
when the Body Control Modul e grounds the rel ay
coi l . See the Di agnosi s and Testi ng secti on of thi s
group for more i nbformati on on the operati on of the
park l amp rel ay.
The park l amp rel ay i s l ocated i n the juncti on
ment panel i n the passenger compartment. The park
l amp rel ay can be accessed by removi ng the fuse
access panel and the ri ght cowl si de tri m panel .
The park l amp rel ay cannot be repai red and, i f
SET LAMP
The VTSS set l amp i s a red l i ght-emi tti ng di ode
mounted wi th the auto headl amp ambi ent l i ght sen-
sor on top of the i nstrument panel near the dri vers
si de defroster outl et. The set l amp recei ves fused bat-
tery feed at al l ti mes and i s grounded by the body
control modul e to gi ve a vi si bl e i ndi cati on of the
VTSS status.
The set l amp cannot be repai red and, i f damaged
or faul ty, the set l amp/auto headl amp ambi ent l i ght
sensor must be repl aced as a uni t.
IMMOBILIZER SYSTEM
The I mmobi l i zer System prevents unauthori zed
operati on of the vehi cl e by di sabl i ng the engi ne. The
system wi l l NOT al l ow the vehi cl e to start unl ess the
UNLOCK button on the RKE transmi tter i s pressed.
The system wi l l be acti vated after turni ng the i gni -
ti on swi tch to the OFF posi ti on and usi ng one of the
fol l owi ng methods.
(1) Press the LOCK button on the RKE transmi t-
ter.
(2) LOCK the doors by pressi ng a power l ock but-
ton swi tch.
(3) LOCK the dri ver or passenger door usi ng the
key.
The Securi ty l i ght wi l l fl ash, for about 16 sec-
onds, i ndi cati ng that the engi ne wi l l be di sabl ed.
The Securi ty l i ght remai ni ng on, i ndi cates the
system i s not operati onal .
The I mmobi l i zer wi l l acti vate automati cal l y
wi thi n 10 mi nutes of the i gni ti on swi tch bei ng i n the
OFF posi ti on, whether the vehi cl e has been l ocked or
unl ocked.
An attempt to start the vehi cl e wi thout pressi ng
the UNLOCK button on the RKE transmi tter wi l l
resul t i n a warni ng chi me and the Securi ty l i ght
fl ashi ng.
NOTE: The ignition switch must be in the OFF posi-
tion in order for the system to be activated, whether
the doors are closed or not.
IMMOBILIZER RECEIVER
The i mmobi l i zer recei ver i s programmed to
respond to the Lock and Unl ock radi o si gnal s i ssued
by the i mmobi l i zer transmi tters. The recei ver wi l l
onl y respond to the radi o si gnal s of transmi tters (up
to four) whose vehi cl e access codes have been stored
i n the recei vers el ectroni c memory. The recei ver i s
programmed at the assembl y pl ant wi th the vehi cl e
access codes of the two transmi tters that are shi pped
wi th the vehi cl e.
The i mmobi l i zer recei ver al so has a central pro-
cessi ng uni t, whi ch contai ns the i mmobi l i zer system
l ogi c. The programmi ng i n the i mmobi l i zer recei ver
al l ows the system to l earn and retai n transmi tter
vehi cl e access codes, as wel l as to communi cate wi th
the Powertrai n Control Modul e (PCM) and/or the
DRB scan tool on the Chrysl er Col l i si on Detecti on
(CCD) data bus network.
sensor i nformati on. Thi s hel ps to reduce wi ri ng har-
same ti me, the CCD data bus network provi des
i ncreased rel i abi l i ty and enhanced di agnosti c capabi l -
i ti es.
Each i mmobi l i zer transmi tter has a di fferent vehi -
cl e access code, whi ch must be programmed i nto the
memory of the i mmobi l i zer recei ver i n the vehi cl e i n
order to operate the i mmobi l i zer system. A DRB scan
tool must be used to program new or addi ti onal
transmi tter vehi cl e access codes i nto the memory of
the i mmobi l i zer recei ver. Refer to the Vehi cl e Theft
Securi ty System menu i tem on the DRB scan tool for
the procedures.
The i mmobi l i zer recei ver recogni zes the Lock and
Unl ock si gnal s recei ved from the programmed i mmo-
bi l i zer transmi tters. The recei ver then uses the pro-
grammed i mmobi l i zer system l ogi c to deci de whether
other moni tored condi ti ons are proper for an engi ne
Lock or Unl ock message to be sent. I f the pro-
grammed condi ti ons are met, the recei ver responds
by sendi ng the proper message to the PCM on the
CCD data bus. The PCM responds to the message by
di sabl i ng or enabl i ng the fuel i njector dri ver ci rcui try
wi thi n the PCM, whi ch wi l l i nhi bi t engi ne operati on.
The i mmobi l i zer recei ver i s mounted to the dash
panel wi th a hook and l oop fastener patch. I t i s
l ocated behi nd the i nstrument cl uster and above the
dri ver si de end of the heater-A/C housi ng. The
recei ver i s connected to the dash panel cross-body
wi ri ng harness.
For di agnosi s of the vehi cl e i mmobi l i zer recei ver or
the CCD data bus, a DRB scan tool i s requi red. Refer
to the Vehi cl e Theft Securi ty System menu i tem of
the DRB scan tool for the procedures. The i mmobi -
l i zer recei ver cannot be repai red and, i f faul ty, the
uni t must be repl aced.
IMMOBILIZER TRANSMITTER
The vehi cl e i mmobi l i zer system i ncl udes two trans-
mi tters that are suppl i ed wi th the vehi cl e when i t i s
shi pped from the factory. Each of the two transmi t-
ters i s equi pped wi th two buttons l abel ed wi th I nter-
nati onal Standards Organi zati on (I SO) symbol s for
Lock, and Unl ock. Two spare batteri es (enough for
one transmi tter) are al so shi pped wi th the transmi t-
ters. The transmi tters are equi pped wi th a key ri ng
and are desi gned to serve as a key fob. The operati ng
range of the radi o frequency transmi tter si gnal i s up
to 7 meters (23 feet) from the i mmobi l i zer recei ver.
Each transmi tter has a di fferent vehi cl e access
code, whi ch must be programmed i nto the memory of
the i mmobi l i zer recei ver i n the vehi cl e i n order to
operate the i mmobi l i zer system. The two transmi t-
ters shi pped wi th the vehi cl e have thei r vehi cl e
access codes programmed i nto the recei ver at the fac-
tory. A DRB scan tool must be used to program new
or addi ti onal transmi tter vehi cl e access codes i nto
the memory of the i mmobi l i zer recei ver. Refer to the
Vehi cl e Theft Securi ty System menu i tem on the
DRB scan tool for the procedures.
Each transmi tter operates on two Duracel l DL2016
(or equi val ent) batteri es. Typi cal battery l i fe i s from
one to two years.
POWER-UP MODE
When the vehi cl e i mmobi l i zer system senses that
the vehi cl e battery has been di sconnected and recon-
nected, i t enters i ts power-up mode. I f the i mmobi -
l i zer system was armed pri or to the battery
di sconnect, the system remai ns armed when the bat-
tery i s reconnected.
I f the i mmobi l i zer system was di sarmed pri or to
the battery di sconnect, the system wi l l remai n di s-
armed i f the battery i s reconnected wi thi n fi ve mi n-
utes. The system wi l l passi vel y arm i tsel f when the
battery i s reconnected more than fi ve mi nutes after a
battery di sconnect or fai l ure. After any passi ve arm-
i ng, the system wi l l have to be acti vel y di sarmed
usi ng one of the transmi tters.
The power-up mode l ogi c al so appl i es i f the battery
goes dead, and battery jump-starti ng i s attempted.
The engi ne no-run feature wi l l prevent the engi ne
from operati ng unti l the vehi cl e i mmobi l i zer system
has been acti vel y di sarmed.
The vehi cl e theft securi ty system shoul d be di ag-
nosed usi ng the DRB scan tool and the proper Body
Di agnosti c Procedures Manual . Refer to 8W-39 -
Vehi cl e Theft Securi ty System i n Group 8W - Wi ri ng
grams.
Self-Diagnostic s
The vehi cl e theft securi ty system has a sel f-di ag-
nosti c mode that can be entered usi ng the DRB scan
tool . Refer to the proper Body Di agnosti c Procedures
Manual for more i nformati on on thi s feature.
RELAYS
Center (PDC) i n the engi ne compartment. The auto
headl amp and park l amp rel ays are l ocated i n the
juncti on bl ock i n the passenger compartment. Each
of these rel ays can be tested as descri bed i n the fol -
l owi ng procedure, however the ci rcui ts they are used
i n do vary. To test the rel ay ci rcui ts, refer to the ci r-
cui t descri pti ons and di agrams i n 8W-39 - Vehi cl e
grams.
INJURY.
Remove the rel ay from the PDC or juncti on bl ock
tests:
and 30. I f OK, test the rel ay ci rcui ts. I f not OK,
repl ace the faul ty rel ay.
Relay Terminals
SERVICE PROCEDURES
INJURY.
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Vehicle Immobilizer System involves the use of a
DRB scan tool. Refer to the Vehicle Theft Security
System menu item on the DRB scan tool for the
procedures.
The vehi cl e i mmobi l i zer system and the Chrysl er
Col l i si on Detecti on (CCD) data bus network shoul d
be di agnosed usi ng the DRB scan tool . The DRB wi l l
al l ow confi rmati on that the CCD data bus i s func-
ti onal , that the i mmobi l i zer recei ver i s pl aci ng the
proper messages on the CCD data bus, and that the
Powertrai n Control Modul e (PCM) i s recei vi ng the
CCD data bus messages. Refer to the Vehi cl e Theft
Securi ty System menu i tem on the DRB scan tool for
the procedures. Refer to 8W-39 - Vehi cl e Theft Secu-
ri ty System i n Group 8W - Wi ri ng Di agrams for com-
pl ete ci rcui t descri pti ons and di agrams.
(1) Wi th the i gni ti on swi tch i n the Off posi ti on,
depress the Lock or Unl ock button of the i mmobi l i zer
transmi tter. Li sten for the i mmobi l i zer recei ver to
i ssue an audi bl e chi rp (Unl ock) or chi rps (Lock). I f
OK, go to Step 2. I f not OK, repl ace the transmi tter
batteri es wi th known good uni ts and repeat Step 1. I f
sti l l not OK, go to Step 2.
(2) Check the fuse i n the Power Di stri buti on Cen-
ter (PDC). I f OK, go to Step 3. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
cabl e. Unpl ug the wi re harness connector at the
i mmobi l i zer recei ver. Check for conti nui ty between
the ground ci rcui t cavi ty of the i mmobi l i zer recei ver
repai r the open ci rcui t to ground as requi red.
i mmobi l i zer recei ver wi re harness connector. I f OK,
refer to the Vehi cl e Theft Securi ty System menu i tem
on the DRB scan tool for further di agnosi s. I f not
OK, repai r the open ci rcui t to the PDC fuse as
requi red.
ENABLING
The vehi cl e i mmobi l i zer system i s di sabl ed when i t
i s shi pped from the factory. Thi s i s done by program-
mi ng wi thi n the Powertrai n Control Modul e (PCM).
The l ogi c i n the PCM prevents the i mmobi l i zer sys-
tem from armi ng unti l the engi ne start counter
wi thi n the PCM sees twenty engi ne starts. The sys-
tem must be enabl ed when the vehi cl e i s recei ved
from the assembl y pl ant.
The preferred method for enabl i ng the i mmobi l i zer
system i s to el ectroni cal l y advance the PCM engi ne
start counter usi ng a DRB scan tool . Refer to the
Vehi cl e Theft Securi ty System menu i tem on the
DRB scan tool for the procedures. Once thi s condi ti on
has been met, the PCM wi l l al l ow the i mmobi l i zer
system to arm.
I f a DRB scan tool i s not avai l abl e, the i mmobi l i zer
system can be enabl ed manual l y, as fol l ows:
(1) I f fi ve mi nutes or more have el apsed si nce the
l ast previ ous engi ne start, or i f the vehi cl e i mmobi -
l i zer recei ver has been acti vel y armed, depress the
vehi cl e i mmobi l i zer transmi tter Unl ock button. Li s-
ten for a si ngl e audi bl e chi rp from the i mmobi l i zer
recei ver to confi rm the Unl ock message has been
recei ved.
(2) Start the engi ne. Each engi ne start must be
fol l owed by a mi ni mum engi ne run durati on of ten
seconds.
(3) Al l owi ng a cool -down peri od between starts, go
back to Step 1 a total of twenty ti mes. After twenty
cycl es, confi rm that the vehi cl e i mmobi l i zer system i s
enabl ed by acti vel y armi ng the recei ver and attempt-
i ng to start the engi ne. The engi ne may start
momentari l y, but shoul d stal l above about 500 rpm.
CAUTION: Repeated sequential starts of the engine
to run up the PCM engine start counter and enable
the immobilizer system must be avoided. Overheat-
ing and damage to the starting system components
and wiring can result.
The same i mmobi l i zer system enabl e l ogi c wi l l
appl y anyti me the PCM i s repl aced wi th a new uni t.
IMMOBILIZER RECEIVER
INJURY.
cabl e.
Group 8E - I nstrument Panel Systems.
(3) Reach through the i nboard si de of the i nstru-
ment cl uster openi ng and remove the recei ver by
pul l i ng i t off of the hook and l oop fastener patch on
the dash panel above the heater-A/C housi ng (Fi g. 1).
(4) Unpl ug the i mmobi l i zer recei ver from the wi re
harness connector.
(6) Refer to the Vehi cl e Theft Securi ty System
menu i tem on the DRB scan tool for the procedures
to program transmi tter vehi cl e access codes i nto the
memory of the new i mmobi l i zer recei ver.
HOOD SWITCH
cabl e.
(2) Remove the screw securi ng the hood swi tch to
the ri ght i nner fender l edge (Fi g. 2).
(3) Unpl ug the wi re connector from the swi tch.
(4) Remove the swi tch from the mounti ng hol e i n
the i nner fender l edge.
l bs.).
DOOR AJAR SWITCH
cabl e.
(2) Remove the screw that secures the door ajar
swi tch to the pi l l ar at the rear of the door openi ng
(Fi g. 3).
Fig. 1 Immobilizer Receiver Remove/Install
Fig. 2 Hood Switch Remove/Install
Fig. 3 Door Ajar Switch Remove/Install
(3) Pul l the swi tch from the mounti ng hol e i n the
door openi ng far enough to access the wi re harness
connector.
swi tch.
l bs.).
cabl e.
door modul e and set the tri m panel asi de.
(8) Pul l the watershi el d away from the rear access
hol es i n the i nner door panel .
(9) Remove the U-cl i p retai ner that secures the
l ock cyl i nder to the outer door panel (Fi g. 5).
(10) Di sconnect the l ock cyl i nder rod from the door
l atch by unsnappi ng the retai ner from the rod.
(11) Pul l the l ock cyl i nder out from the outer door
panel far enough to pry the l ock cyl i nder swi tch off of
the back of the l ock cyl i nder (Fi g. 6).
connector and remove the swi tch from i nsi de the
door.
Fig. 5 Door Lock Cylinder Remove/Install
Fig. 6 Door Lock Cylinder Switch Remove/Install -
Typical
cabl e.
(4) Remove the three screws that secure the l i ft-
gate l atch to the l i ftgate (Fi g. 8).
(5) Di sconnect the l i ftgate handl e l atch actuator
rod from the l atch.
(6) Unpl ug the l i ftgate ajar swi tch wi re harness
connector from the l atch.
(7) Remove the l atch from the l i ftgate.
Ti ghten the l atch mounti ng screws to 7 Nm (62 i n
l bs.).
cabl e.
(4) Pry the l i ftgate l ock cyl i nder swi tch off of the
back of the l ock cyl i nder (Fi g. 10).
connector and remove the swi tch from i nsi de the l i ft-
gate.
Fig. 8 Liftgate Latch/Lock Components
Fig. 10 Liftgate Lock Cylinder Switch Remove/Install
cabl e.
(4) Remove the two nuts that secure the l i ftgl ass
l atch to the l i ftgate i nner panel (Fi g. 12).
(5) Unpl ug the wi re harness connectors for the l i ft-
gl ass l atch sol enoi d and the l i ftgl ass ajar swi tch.
(6) Remove the l i ftgl ass l atch from the l i ftgate.
Ti ghten the l atch mounti ng nuts to 11 Nm (100 i n.
l bs.).
AUTO HEADLAMP AND PARK LAMP RELAYS
INJURY.
cabl e.
cowl si de tri m to the ri ght front door openi ng tri m.
(6) Unpl ug the headl amp or park l amp rel ay from
the juncti on bl ock.
(7) I nstal l the headl amp or park l amp rel ay by
al i gni ng the rel ay termi nal s wi th the cavi ti es i n the
juncti on bl ock and pushi ng the rel ay fi rml y i nto
pl ace.
Fig. 12 Liftglass Ajar Switch Remove/Install
Fig. 13 Right Cowl Side Trim Remove/Install
(10) I nstal l the ri ght cowl si de tri m and the fuse
access panel .
HORN RELAY
cabl e.
SET LAMP
INJURY.
cabl e.
sti ck, pry the cowl top tri m panel off of the i nstru-
ment panel top pad (Fi g. 15).
far enough to unpl ug the wi re harness connector
from the sol ar sensor, or to remove the sol ar sensor
from the cowl top tri m between the passenger si de
and center defroster outl ets.
cl e.
(5) Remove the auto headl amp l i ght sensor/vehi cl e
theft securi ty system set l amp mounti ng screw near
the dri ver si de defroster duct outl et.
(6) Pul l the l amp up far enough to unpl ug the wi re
harness connector and remove the l amp.
POWER SEAT SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 3
MEMORY SEAT MODULE . . . . . . . . . . . . . . . . . 2
POWER LUMBAR ADJUSTER AND MOTOR . . . 3
POWER LUMBAR SWITCH . . . . . . . . . . . . . . . . 2
POWER RECLINER ADJUSTER AND MOTOR . . 2
POWER SEAT ADJUSTER AND MOTORS . . . . . 2
POWER SEAT SWITCH . . . . . . . . . . . . . . . . . . . 2
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 3
POWER SEAT SYSTEM . . . . . . . . . . . . . . . . . . . 3
MEMORY SEAT MODULE . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
INTRODUCTION
Si x-way dri ver and passenger power front seats
wi th power recl i ners and power l umbar supports are
an avai l abl e factory-i nstal l ed opti on for thi s model .
The power seat system recei ves battery feed through
a fuse i n the Power Di stri buti on Center (PDC) and a
ci rcui t breaker i n the juncti on bl ock at al l ti mes.
components i n the power seat system. Refer to 8W-63
- Power Seat i n Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams.
MEMORY SYSTEM
mi tter.
recal l .
procedures for the power seat system components.
For di agnosi s of the memory system, use of a DRB
scan tool and the proper Body Di agnosti c Procedures
manual are recommended. For addi ti onal i nformati on
on the features and functi ons of the memory system,
ZG POWER SEAT SYSTEMS 8R - 1
MEMORY SEAT MODULE
A Memory Seat Modul e (MSM), mounted under the
i nboard si de of the dri ver si de front seat cushi on, i s
used on thi s model to control al l of the dri ver si de
power seat memory functi ons and features. The MSM
contai ns a central processi ng uni t and i nterfaces wi th
The MSM recei ves hard-wi red i nputs from the
power seat swi tch, the power l umbar swi tch, and the
potenti ometers on each of the dri ver si de power seat
motors. The MSM recei ves messages on the CCD
data bus from the Dri ver Door Modul e (DDM) (mem-
ory set/sel ect swi tch status), the Powertrai n Control
Modul e (PCM) (vehi cl e speed status), and the Body
Control Modul e (seat bel t swi tch status). The pro-
grammi ng i n the MSM al l ows i t to process the i nfor-
mati on from these i nputs and send control outputs to
each of the dri ver si de power seat motors. The MSM
wi l l prevent the seat memory functi on from bei ng i ni -
ti ated i f the dri ver si de seat bel t i s buckl ed, or i f the
vehi cl e i s movi ng.
For di agnosi s of the MSM or the CCD data bus,
refer to the proper Body Di agnosti c Procedures man-
ual . The MSM cannot be repai red and, i f faul ty, i t
must be repl aced.
POWER SEAT SWITCH
The power seat can be adjusted i n ei ght di fferent
ways usi ng the power seat swi tch. The swi tch i s
l ocated at the l ower outboard si de of the seat cushi on
on the seat cushi on si de shi el d. Refer to the owners
manual for more i nformati on on the power seat
swi tch functi ons and the seat adjusti ng procedures.
The i ndi vi dual swi tches i n the power seat swi tch
modul e cannot be repai red. I f one swi tch i s damaged
or faul ty, the enti re power seat swi tch modul e must
be repl aced.
POWER LUMBAR SWITCH
The power l umbar adjuster on each front seat can
be moved i n or out el ectri cal l y by operati ng the si n-
gl e two-way swi tch mounted near the front of the
outboard seat cushi on si de shi el d.
The power l umbar swi tches cannot be repai red
POWER SEAT ADJUSTER AND MOTORS
There are three reversi bl e motors that operate the
power seat adjuster. The motors are connected to
worm-dri ve gearboxes that move the seat adjuster
through a combi nati on of screw-type dri ve uni ts.
The front and rear of a seat are operated by di ffer-
ent motors. They can be rai sed or l owered i ndepen-
dentl y of each other. When the seat swi tch i s pushed
to the Up or Down posi ti on, both the front and rear
motors operate i n uni son, movi ng the enti re seat up
or down. The forward-rearward motor i s operated by
pushi ng the seat swi tch to i ts forward or rearward
posi ti on.
When a swi tch i s actuated, a battery feed and a
ground path are appl i ed through the swi tch contacts
to the motor(s). The motor(s) operate to move the
seat i n the sel ected di recti on unti l the swi tch i s
rel eased, or unti l the travel l i mi t of the power seat
adjuster i s reached. When the swi tch i s moved i n the
opposi te di recti on, the battery feed and ground paths
to the motor(s) are reversed through the swi tch con-
tacts. Thi s causes the motor to run i n the opposi te
di recti on.
Each motor contai ns a sel f-resetti ng ci rcui t breaker
to protect i t from overl oad. Consecuti ve or frequent
resetti ng of the ci rcui t breakers must not be al l owed
to conti nue, or the motors may be damaged. Make
the necessary repai rs. The motors used on model s
wi th the opti onal memory system al so have a posi -
ti on potenti ometer i ncl uded i n the motor assembl y.
The power seat adjuster and motors cannot be
repai red, and are servi ced onl y as a compl ete uni t. I f
any component i n thi s uni t i s faul ty or damaged, the
enti re power seat adjuster and motors assembl y must
be repl aced.
POWER RECLINER ADJUSTER AND MOTOR
The power recl i ner adjuster uses a reversi bl e motor
to operate the seat back recl i ner adjuster. The motor
i s connected to a gearbox that moves the recl i ner
adjuster through a screw-type dri ve uni t.
When the power recl i ner swi tch i s actuated, a bat-
tery feed and a ground path are appl i ed through the
swi tch contacts to the motor. The motor operates to
move the seat back i n the sel ected di recti on unti l the
swi tch i s rel eased, or unti l the travel l i mi t of the
power recl i ner adjuster i s reached. When the swi tch
i s moved i n the opposi te di recti on, the battery feed
and ground paths to the motor are reversed through
the swi tch contacts. Thi s causes the motor to run i n
the opposi te di recti on.
The motor contai ns a sel f-resetti ng ci rcui t breaker
resetti ng of the ci rcui t breaker must not be al l owed
to conti nue, or the motor may be damaged. Make the
necessary repai rs. The motor used on model s wi th
the opti onal memory system al so has a posi ti on
potenti ometer i ncl uded i n the motor assembl y.
The power recl i ner adjuster and motor cannot be
repai red, and i s servi ced onl y as a compl ete uni t. I f
any component i n thi s uni t i s faul ty or damaged, the
enti re power recl i ner adjuster and motor assembl y
must be repl aced.
8R - 2 POWER SEAT SYSTEMS ZG
POWER LUMBAR ADJUSTER AND MOTOR
There i s a reversi bl e motor that operates the power
l umbar adjuster. The motor i s connected to a worm-
dri ve gearbox that moves the l umbar adjuster mech-
ani sm through a cabl e and l ever-type actuator uni t.
When the power l umbar swi tch i s actuated, a bat-
tery feed and a ground path are appl i ed through the
swi tch contacts to the motor. The motor operates to
move the l umbar adjuster mechani sm i n the sel ected
di recti on unti l the swi tch i s rel eased, or unti l the
travel l i mi t of the l umbar adjuster i s reached. When
the swi tch i s moved i n the opposi te di recti on, the
battery feed and ground paths to the motor are
reversed through the swi tch contacts. Thi s causes the
motor to run i n the opposi te di recti on.
The motor contai ns a sel f-resetti ng ci rcui t breaker
resetti ng of the ci rcui t breaker must not be al l owed
to conti nue, or the motor may be damaged. Make the
necessary repai rs. The motor used on model s wi th
the opti onal memory system al so has a posi ti on
potenti ometer i ncl uded i n the motor assembl y.
The power l umbar adjuster and motor cannot be
repai red, and are servi ced onl y as a compl ete uni t
wi th the seat back frame. I f any component i n thi s
uni t i s damaged or i s faul ty, the enti re power l umbar
seat back frame assembl y must be repl aced.
CIRCUIT BREAKER
ti on bl ock i s used to protect the power seat system
ci rcui t. The ci rcui t breaker can protect the system
from a short ci rcui t, or from an overl oad condi ti on
caused by an obstructed or stuck seat adjuster.
POWER SEAT SYSTEM
Before any testi ng of the power seat system i s
attempted, the battery shoul d be ful l y-charged and
al l wi re harness connecti ons and pi ns cl eaned and
ti ghtened to ensure proper conti nui ty and grounds.
- Power Seat i n Group 8W - Wi ri ng Di agrams.
Wi th the dome l amp on, appl y the power seat
swi tch i n the di recti on of the fai l ure. I f the dome
l amp di ms, the seat may be jammi ng. Check under
and behi nd the seat for bi ndi ng or obstructi ons. I f
the dome l amp does not di m, proceed wi th testi ng of
the i ndi vi dual components and ci rcui ts.
CIRCUIT BREAKER
8W-63 - Power Seat i n Group 8W - Wi ri ng Di agrams.
i n the juncti on bl ock cavi ti es.
requi red.
POWER SEAT SWITCH
(1) Remove the power seat swi tch as descri bed i n
thi s group.
(2) Use an ohmmeter to test the conti nui ty of the
swi tches i n each posi ti on. See the Power Seat Swi tch
Conti nui ty chart (Fi g. 1). I f OK, see the di agnosi s for
the Power Seat Adjuster and Motors or Power
Recl i ner Adjuster and Motor, as requi red. I f not OK,
repl ace the faul ty swi tch modul e.
POWER LUMBAR SWITCH
(1) Remove the power l umbar swi tch as descri bed
i n thi s group.
(2) Use an ohmmeter to test the conti nui ty of the
swi tch i n each posi ti on. See the Power Lumbar
Swi tch Conti nui ty chart (Fi g. 2). I f OK, see the di ag-
nosi s for the Power Lumbar Adjuster and Motor. I f
not OK, repl ace the faul ty swi tch.
The tests bel ow appl y to a power seat system wi th-
out the memory system opti on. For testi ng of the
power seats wi th the memory system, refer to the
Power Seat i n Group 8W - Wi ri ng Di agrams.
Operate the power seat swi tch to move al l three
seat motors. The seat shoul d move i n each sel ected
di recti on. I f a motor fai l s to operate i n onl y one di rec-
ti on, move the seat a short di stance i n the opposi te
di recti on and test agai n to be certai n the adjuster i s
not at i ts travel l i mi t. I f one or more of the motors
operate, see the di agnosi s for the Power Seat Swi tch
i n thi s group. I f no motors operate, proceed as fol -
l ows:
(1) Test the ci rcui t breaker i n the juncti on bl ock as
descri bed i n thi s group. I f OK, go to Step 2. I f not
thi s group. Check for battery vol tage at the fused
B(+) ci rcui t cavi ty of the swi tch wi re harness connec-
ci rcui t to the juncti on bl ock as requi red.
to Step 4. I f not OK, repai r the open ci rcui t to ground
as requi red.
(4) Test the power seat swi tch as descri bed i n thi s
group. I f the swi tch tests OK, check the wi re harness
for the i noperati ve motor between the swi tch and the
motor for shorts or opens. I f the ci rcui ts check OK,
repl ace the faul ty power seat adjuster and motors
assembl y. I f the ci rcui ts are not OK, repai r the wi re
harness as requi red.
Operate the power seat swi tch to move the power
recl i ner i n each di recti on. The recl i ner shoul d move
i n both di recti ons. I f the power recl i ner fai l s to oper-
ate i n onl y one di recti on, move the seat a short di s-
tance i n the opposi te di recti on and test agai n to be
certai n the adjuster i s not at i ts travel l i mi t. I f the
power recl i ner sti l l fai l s to operate i n onl y one di rec-
ti on, see the di agnosi s for the Power Seat Swi tch i n
thi s group. I f the power recl i ner fai l s to operate i n
ei ther di recti on, proceed as fol l ows:
thi s group. Check for battery vol tage at the fused
as requi red.
Fig. 1 Power Seat Switch Continuity
Fig. 2 Power Lumbar Switch Continuity
(4) Test the power seat swi tch as descri bed i n thi s
group. I f the swi tch tests OK, check the wi re harness
for the power recl i ner between the swi tch and the
motor for shorts or opens. I f the ci rcui ts check OK,
repl ace the faul ty power recl i ner adjuster and motor
assembl y. I f the ci rcui ts are not OK, repai r the wi re
harness as requi red.
Operate the power l umbar swi tch to move the
power l umbar adjuster i n each di recti on. The l umbar
adjuster shoul d move i n both di recti ons. I f the power
l umbar adjuster fai l s to operate i n onl y one di recti on,
move the adjuster a short di stance i n the opposi te
di recti on and test agai n to be certai n the adjuster i s
not at i ts travel l i mi t. I f the l umbar adjuster sti l l
fai l s to operate i n onl y one di recti on, see the di agno-
si s for the Power Lumbar Swi tch i n thi s group. I f the
power l umbar adjuster fai l s to operate i n ei ther
di recti on, proceed as fol l ows:
(2) Remove the power l umbar swi tch as descri bed
i n thi s group. Check for battery vol tage at the fused
as requi red.
(4) Test the power l umbar swi tch as descri bed i n
thi s group. I f the swi tch tests OK, check the wi re
harness for the power l umbar adjuster between the
swi tch and the motor for shorts or opens. I f the ci r-
cui ts check OK, repl ace the faul ty power l umbar
adjuster and motor, whi ch are servi ced wi th the seat
back frame assembl y. I f the ci rcui ts are not OK,
repai r the wi re harness as requi red.
POWER SEAT SWITCH
cabl e.
bl aded tool , gentl y pry the power seat and power
recl i ner swi tch knobs off of the swi tch stems.
cushi on si de shi el d to the seat cushi on frame.
(4) Pul l the si de shi el d away from the seat cushi on
far enough to unpl ug the swi tch wi re harness connec-
tor.
(5) Remove the two screws that secure the swi tch
to the i nsi de of the si de shi el d (Fi g. 3).
(6) Remove the swi tch from the si de shi el d.
POWER LUMBAR SWITCH
cabl e.
cushi on si de shi el d to the seat cushi on frame.
(3) Pul l the si de shi el d away from the seat cushi on
far enough to unpl ug the swi tch wi re harness connec-
tor.
(4) Remove the two screws that secure the swi tch
to the i nsi de of the si de shi el d.
(5) Remove the swi tch from the si de shi el d.
(1) Move the seat to the forward-most posi ti on, i f
possi bl e.
(2) Remove the si ngl e screw that secures each of
the two rear seat track covers to the rear of the seat
tracks and remove the covers.
(3) Remove the si ngl e screw that secures the rear
of each of the two seat tracks to the fl oor pan.
(4) Move the seat to the rearward-most posi ti on, i f
possi bl e.
cabl e.
(6) Remove the si ngl e screw that secures the front
of each of the two seat tracks to the fl oor pan (Fi g.
4).
(7) Ti l t the seat rearward and unpl ug the power
seat wi re harness connector l ocated under the seat
cushi on.
(8) Remove the seat assembl y from the vehi cl e.
Fig. 3 Power Seat Switches Remove/Install
POWER SEAT/RECLINER SWITCH POWER LUMBAR SWITCH SEAT CUSHION SIDE SHIELD
(9) Remove the three screws that secure the out-
board seat cushi on si de shi el d to the seat cushi on
frame and pul l the shi el d away from the seat cush-
i on.
(10) Remove the four nuts that secure the upper
seat adjuster mounti ng rai l s to the seat cushi on
frame.
(11) Unpl ug the wi re harness connectors as
requi red, dependi ng upon how the vehi cl e i s
equi pped, to separate the power seat motors and
adjuster from the seat cushi on frame.
Ti ghten the seat mounti ng hardware as fol l ows:
Seat cushi on frame to adjuster nuts - 20 Nm (15
ft. l bs.)
Seat adjuster to fl oor pan bol ts - 29 Nm (20 ft.
l bs.).
(1) Move the power seat adjuster to the most
rai sed and forward stop posi ti ons, i f possi bl e.
(2) Remove the three screws that secure the out-
board seat cushi on si de shi el d to the seat cushi on
frame and pul l the shi el d away from the seat so that
the power recl i ner adjuster l ower bracket can be
seen.
(3) I f possi bl e, adjust the seat back wi th the power
recl i ner swi tch far enough so that both of the two
bol ts i n the power recl i ner adjuster l ower bracket can
be accessed.
cabl e.
(5) Remove the two bol ts that secure the power
recl i ner adjuster l ower bracket to the seat cushi on
frame (Fi g. 5).
(6) Remove the i nboard seat back pi vot bol t.
(7) Unpl ug the wi re harness connectors, dependi ng
upon how the vehi cl e i s equi pped, as requi red to
remove the seat back from the seat cushi on.
(8) Remove the seat back cover far enough to
access the two bol ts that secure the power recl i ner
adjuster upper bracket to the seat back frame (Fi g.
6). Refer to Group 23 - Body for the seat back cover
removal procedures.
(9) Remove the power recl i ner adjuster and motor
uni t from the seat back frame.
I nboard pi vot bol t - 40 Nm (29 ft. l bs.)
Recl i ner bracket bol ts - 28 Nm (20 ft. l bs.).
(1) Remove the power recl i ner adjuster and motor
from the seat back frame as descri bed i n thi s group.
(2) Remove al l of the seat back tri m from the seat
back. Refer to Group 23 - Body for the procedures.
Fig. 4 Power Seat Remove/Install - Typical
POWER SEAT FWD SCREWS (4)
Fig. 5 Power Recliner Lower Bracket Remove/Install
POWER RECLINER ADJUSTER HEATED SEAT CONTROL MODULE MOUNTING SCREW SEAT CUSHION FRAME
Fig. 6 Power Recliner Upper Bracket Remove/Install
SEATBACK DUONCOVER RECLINER SEAT BACK FRAME
(3) Repl ace the seat back frame assembl y, whi ch
i ncl udes the l umbar adjuster and motor (Fi g. 7).
MEMORY SEAT MODULE
(1) Move the dri ver si de power seat adjuster to the
most rai sed and forward stop posi ti ons, i f possi bl e.
(2) Remove the si ngl e screw that secures each of
the two rear seat track covers to the rear of the seat
tracks and remove the covers.
(3) Remove the si ngl e screw that secures the rear
(4) Move the dri ver si de power seat adjuster to the
most rearward stop posi ti on, i f possi bl e.
(5) Remove the si ngl e screw that secures the front
cabl e.
(7) Careful l y ti l t the seat back towards the out-
board si de of the vehi cl e.
(8) Rel ease the two retai ners that secure the mem-
ory seat modul e wi re harness to the i nboard seat
adjuster top rai l (Fi g. 8).
(9) Sl i de the memory seat modul e off of the mount-
i ng bracket sl i de tabs far enough to unpl ug the wi re
harness connectors.
(10) Remove the modul e from under the seat cush-
i on.
NOTE: Following the installation it will be neces-
sary to initialize the memory seat module. This is
done by moving each of the power seat adjuster
motors (including the power recliner and power
lumbar motors) through its full range of motion
using the power seat switches. It is necessary for
the memory seat module to learn the motor sensor
values in each of the adjuster hard stop positions,
so that the module can function properly.
Fig. 7 Power Lumbar Adjuster and Motor
HEAD RESTRAINT SLEEVE GUIDE BACK PANEL LUMBAR U-NUT LUMBAR MOTOR
Fig. 8 Memory Seat Module Remove/Install
BRACKET SLIDE TABS MEMORY SEAT MODULE WIRE HARNESS RETAINERS
POWER WINDOW SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . 1
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 3
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER WINDOW MOTOR . . . . . . . . . . . . . . . . 2
POWER WINDOW SWITCH . . . . . . . . . . . . . . . . 1
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 3
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . 3
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
INTRODUCTION
Power wi ndows are standard factory-i nstal l ed
equi pment on thi s model . Thi s group covers di agnosi s
and servi ce of onl y the el ectri cal components i n the
power wi ndow system. For servi ce of mechani cal
components, such as the regul ator, l i ft pl ate, wi ndow
tracks, or gl ass refer to Group 23 - Body.
components i n the power wi ndow system. Refer to
8W-60 - Power Wi ndows i n Group 8W - Wi ri ng Di a-
Refer to the owners manual for more i nformati on on
the features and use of thi s system.
POWER WINDOW SYSTEM
The power wi ndow system al l ows al l of the door
wi ndows to be opened or cl osed by operati ng a swi tch
on the tri m panel for that door. The master swi tches
on the dri ver si de front door tri m panel can be oper-
ated to open or cl ose any of the door wi ndows. I n
addi ti on, a l ockout swi tch on the dri ver si de front
door tri m panel al l ows the dri ver to di sabl e al l of the
passenger door wi ndow swi tches.
The power wi ndow system i ncl udes the door mod-
ul es mounted i n each front door, the swi tches
mounted on the rear doors, and the power wi ndow
motors mounted to the wi ndow regul ator i n each
door. I n addi ti on, several features and functi ons of
the power wi ndow system are made possi bl e because
of the communi cati on of the door modul es on the
The power wi ndow system operates wi th battery
power suppl i ed through a ci rcui t breaker i n the junc-
ti on bl ock, onl y when the i gni ti on swi tch i s i n the On
posi ti on. However, a feature of thi s system wi l l al l ow
the wi ndows to be operated for up to thi rty seconds
after the i gni ti on swi tch i s turned to the Off posi ti on,
or unti l a front door i s opened, whi chever occurs
fi rst.
An auto-down feature al l ows the dri ver si de front
door wi ndow to be l owered al l the way, even i f the
wi ndow swi tch i s rel eased. The dri ver si de front door
wi ndow swi tch must be depressed i n the down di rec-
ti on to a second detent to begi n an auto-down event.
Depressi ng the swi tch agai n i n any di recti on wi l l
stop the wi ndow movement and cancel the auto-down
event.
POWER WINDOW SWITCH
The power wi ndows are control l ed by a two-way
momentary swi tch mounted on the tri m panel of each
passenger door, and four two-way momentary
swi tches on the dri ver si de front door tri m panel . The
dri ver si de front door tri m panel al so has a two-posi -
ti on power wi ndow l ockout swi tch.
ZG POWER WINDOW SYSTEMS 8S - 1
Each power wi ndow swi tch, except the l ockout
swi tch, i s i l l umi nated by a Li ght-Emi tti ng Di ode
(LED) when the i gni ti on swi tch i s turned to the On
posi ti on. However, when the l ockout swi tch i s pl aced
i n the Lock posi ti on, the LED for the l ocked-out front
and rear passenger door power wi ndow swi tches i s
turned off.
The front door power wi ndow swi tches and the
power wi ndow l ockout swi tch are i ntegral to the
Dri ver Door Modul e (DDM) or Passenger Door Mod-
ul e (PDM), respecti vel y. These power wi ndow
swi tches provi de an up or down (or l ock and unl ock
si gnal i n the case of the l ockout swi tch) to the door
modul e ci rcui try.
dri ver si de front and rear door power wi ndow motors,
and suppl i es el ectri cal current as requi red for opera-
ti on of the dri ver si de rear door power wi ndow
swi tch. The PDM ci rcui try control s the output to the
passenger si de front and rear door power wi ndow
motors, and suppl i es el ectri cal current as requi red
for operati on of the passenger si de rear door power
wi ndow swi tch. When a DDM-i ntegrated power wi n-
dow swi tch for a passenger si de wi ndow i s actuated,
the DDM ci rcui try sends a message to the PDM on
the Chrysl er Col l i si on Detecti on (CCD) data bus to
acti vate the output to that power wi ndow motor(s).
The front door power wi ndow swi tches and thei r
l amps cannot be repai red so, i f faul ty or damaged,
the enti re door modul e must be repl aced. The rear
door power wi ndow swi tches and thei r l amps cannot
be repai red but, i f faul ty or damaged, onl y the
affected swi tch uni t must be repl aced.
DOOR MODULE
bus network.
dri ver si de front and rear door power wi ndows. The
PDM ci rcui try control s the output to the passenger
si de front and rear door power wi ndows. The DDM
can control the PDM output by sendi ng control mes-
sages to the PDM over the CCD data bus.
Some of the features and functi ons of the power
wi ndow system made possi bl e because of the commu-
ni cati on of the door modul es on the CCD data bus
network i ncl ude:
Power wi ndow operati on after i gni ti on off fea-
ture.
Power wi ndow l ockout functi on.
Power wi ndow swi tch LED i l l umi nati on control
functi on.
Procedures manual .
BODY CONTROL MODULE
supports and control s, i s the power wi ndow system.
The BCM recei ves i nputs from the i gni ti on swi tch
and the door ajar swi tches. The programmi ng i n the
BCM al l ows i t to process the i nformati on from these
i nputs and send i gni ti on swi tch and door ajar status
messages to the DDM and PDM on the CCD data
bus. The DDM and PDM use thi s i nformati on to con-
trol the l i ghti ng of the power wi ndow swi tch l amps,
and to control the operati on of the power wi ndow
after i gni ti on off feature.
POWER WINDOW MOTOR
A permanent magnet reversi bl e motor moves the
wi ndow regul ator through an i ntegral gearbox mech-
ani sm. A posi ti ve and negati ve battery connecti on to
the two motor termi nal s wi l l cause the motor to
rotate i n one di recti on. Reversi ng the current
8S - 2 POWER WINDOW SYSTEMS ZG
through these same two connecti ons wi l l cause the
motor to rotate i n the opposi te di recti on.
I n addi ti on, each power wi ndow motor i s equi pped
wi th an i ntegral sel f-resetti ng ci rcui t breaker to pro-
tect the motor from overl oads. The power wi ndow
motor and gearbox assembl y cannot be repai red and,
i f faul ty or damaged, the enti re motor assembl y must
be repl aced.
CIRCUIT BREAKER
ti on bl ock i s used to protect the power wi ndow sys-
tem ci rcui t. The ci rcui t breaker can protect the
system from a short ci rcui t, or from an overl oad con-
di ti on caused by an obstructed or stuck wi ndow gl ass
or regul ator.
POWER WINDOW SYSTEM
ual.
to the dri ver si de front and rear power wi ndow
motors. The PDM ci rcui try control s the output to the
passenger si de front and rear power wi ndow motors.
- Power Wi ndows i n Group 8W - Wi ri ng Di agrams.
ALL WINDOWS INOPERATIVE
(1) Test the ci rcui t breaker i n the juncti on bl ock,
as descri bed i n thi s group. I f OK, go to Step 2. I f not
cabl e. Remove the l eft and ri ght front door tri m pan-
el s. Check the 12-way door modul e wi re harness con-
nectors to see that they are ful l y seated i n the door
modul e receptacl es. I f OK, go to Step 3. I f not OK,
i nstal l the wi re harness connectors properl y.
connectors. Check for conti nui ty between the ground
ci rcui t cavi ty of each door modul e wi re harness con-
nector and a good ground. I f OK, go to Step 4. I f not
battery vol tage at the fused B(+) ci rcui t cavi ty of
each 12-way door modul e wi re harness connector. I f
OK, use a DRB scan tool and the proper Body Di ag-
nosti c Procedures manual to di agnose the door mod-
ul es and the CCD data bus. I f not OK, repai r the
open ci rcui t to the juncti on bl ock as requi red.
ONE WINDOW INOPERATIVE
The wi ndow gl ass must be free to sl i de up and
down for the power wi ndow motor to functi on prop-
erl y. I f the gl ass i s not free to move up and down, the
motor wi l l overl oad and tri p the i ntegral ci rcui t
breaker. To determi ne i f the gl ass i s free, di sconnect
the regul ator pl ate from the gl ass. Then sl i de the
wi ndow up and down by hand.
There i s an al ternate method to check i f the gl ass
i s free. Posi ti on the gl ass between the up and down
stops. Then, shake the gl ass i n the door. Check that
the gl ass can be moved sl i ghtl y from si de to si de,
front to rear, and up and down. Then check that the
gl ass i s not bound ti ght i n the tracks. I f the gl ass i s
free, proceed to the Door Modul e di agnosi s i n thi s
group. I f the gl ass i s not free, refer to Group 23 -
Body for the door wi ndow gl ass and hardware servi ce
and adjustment procedures.
CIRCUIT BREAKER
grams.
i n the juncti on bl ock cavi ti es.
requi red. I f the ci rcui t breaker checks OK, but no
power wi ndows operate, see the di agnosi s for Power
Wi ndow System.
DOOR MODULE
ual.
I f the probl em bei ng di agnosed i s a rear door wi n-
dow that does not operate from the rear door swi tch,
but does operate from the master swi tch on the
dri ver si de front door, go to the di agnosi s for Power
Wi ndow Swi tch i n thi s group. I f the probl em i s a pas-
senger si de front or rear wi ndow that operates from
the swi tch on that door, but does not operate from
the master swi tch on the dri ver si de front door, use a
cedures manual to di agnose the ci rcui try of the door
modul es and the CCD data bus. For ci rcui t descri p-
ti ons and di agrams, refer to 8W-60 - Power Wi ndows
i n Group 8W - Wi ri ng Di agrams.
cabl e. Remove the front door tri m panel as descri bed
i n thi s group. Go to Step 2.
(2) Check the 12-way door modul e wi re harness
connector to see that i t i s ful l y seated i n the door
modul e receptacl e. I f OK, go to Step 3. I f not OK,
i nstal l the wi re harness connector properl y.
connector from the door modul e. Check for conti nui ty
between the ground ci rcui t cavi ty of the door modul e
12-way door modul e wi re harness connector. I f OK,
go to Step 5. I f not OK, repai r the open ci rcui t as
requi red.
(5) I f the i noperati ve wi ndow i s on a front door, go
to Step 6. I f the i noperati ve wi ndow i s on a rear door
go to Step 9.
cabl e. Unpl ug the i noperati ve power wi ndow motor
the front wi ndow dri ver up ci rcui t cavi ty of the
12-way door modul e wi re harness connector and a
good ground. Repeat the check for the front wi ndow
dri ver down ci rcui t cavi ty of the door modul e wi re
harness connector. I n each case there shoul d be no
conti nui ty. I f OK, go to Step 7. I f not OK, repai r the
short ci rcui t as requi red.
(7) Check for conti nui ty between the front wi ndow
dri ver up ci rcui t cavi ti es of the 12-way door modul e
wi re harness connector and the power wi ndow motor
wi re harness connector. Repeat the check for the
front wi ndow dri ver down ci rcui t cavi ti es. I n each
case there shoul d be conti nui ty. I f OK, go to Step 8.
I f not OK, repai r the open ci rcui t as requi red.
(8) Pl ug the 12-way door modul e wi re harness con-
nector back i nto the door modul e. Connect the bat-
tery negati ve cabl e. Connect the probes of a
reversi bl e DC di gi tal vol tmeter to the door modul e
si de of the power wi ndow motor wi re harness connec-
tor. Observe the vol tmeter whi l e actuati ng the swi tch
i n the up and down di recti ons. There shoul d be bat-
tery vol tage for as l ong as the swi tch i s hel d i n both
the up and down posi ti ons, and no vol tage i n the
neutral posi ti on. I f OK, see the di agnosi s for Power
Wi ndow Motors. I f not OK, repl ace the faul ty door
modul e.
cabl e. Remove the rear door power wi ndow swi tch as
descri bed i n thi s group. Check the rear door power
wi ndow swi tch conti nui ty as descri bed i n thi s group.
swi tch.
(10) Pl ug the rear door power wi ndow swi tch i nto
the wi re harness connector. Unpl ug the i noperati ve
power wi ndow motor connector. Check for conti nui ty
between the rear wi ndow dri ver up ci rcui t cavi ty of
the 12-way door modul e wi re harness connector and
a good ground. Repeat the check for the rear wi ndow
dri ver down ci rcui t cavi ty. I n each case there shoul d
(11) Check for conti nui ty between the rear wi ndow
dri ver up ci rcui t cavi ti es of the 12-way door modul e
wi re harness connector and the power wi ndow motor
wi re harness connector. Repeat the check for the rear
wi ndow dri ver down ci rcui t cavi ti es. I n each case
there shoul d be conti nui ty. I f OK, go to Step 12. I f
NOTE: The door module feeds battery voltage to
both terminals of the rear door power window
motors when the power window lockout switch is in
the Unlock position, until the master window switch
on the driver side front door is actuated. The door
module feeds ground to both terminals of the rear
door power window motor when the power window
lockout switch is in the Lock position, until the
master window switch on the driver side front door
is actuated.
(12) Pl ug the 12-way door modul e wi re harness
connector back i nto the door modul e. Connect the
battery negati ve cabl e. Check for battery vol tage at
each cavi ty of the swi tch si de of the power wi ndow
motor wi re harness connector. Each cavi ty shoul d
have battery vol tage i n the neutral posi ti on. Each
cavi ty shoul d al so have battery vol tage i n one other
swi tch posi ti on, ei ther up or down, and zero vol ts
wi th the swi tch i n the opposi te posi ti on. I f OK, go to
the Power Wi ndow Motor di agnosi s i n thi s group. I f
not OK, repl ace the faul ty door modul e.
POWER WINDOW SWITCH
Thi s di agnosi s i s for the rear door power wi ndow
swi tches. The front door power wi ndow swi tches are
i ntegral to the door modul es. For di agnosi s of the
front door power wi ndow swi tches, see Door Modul e
i n thi s group. For ci rcui t descri pti ons and di agrams,
refer to 8W-60 - Power Wi ndows i n Group 8W - Wi r-
i ng Di agrams.
cabl e.
(2) Remove the power wi ndow swi tch from the
rear door tri m panel as descri bed i n thi s group.
(3) Careful l y unpl ug the power wi ndow swi tch
from the wi re harness connector.
(4) Check the swi tch conti nui ty i n each posi ti on, as
shown i n the chart (Fi g. 1). I f OK, see the Power
Wi ndow Motor di agnosi s i n thi s group. I f not OK,
repl ace the faul ty swi tch.
POWER WINDOW MOTOR
grams. Before you proceed wi th thi s di agnosi s, con-
fi rm proper swi tch operati on. See the Door Modul e
and/or Power Wi ndow Swi tch di agnosi s i n thi s group.
(1) Remove the door tri m panel as descri bed i n
Door Modul e (front door) or Power Wi ndow Swi tch
(rear door) i n thi s group.
(2) Di sconnect the power wi ndow motor wi re har-
ness connector. Appl y 12 vol ts across the motor ter-
mi nal s to check i ts operati on i n one di recti on.
Reverse the connecti ons across the motor termi nal s
to check the operati on i n the other di recti on. Remem-
ber, i f the wi ndow i s i n the ful l up or ful l down posi -
ti on, the motor wi l l not operate i n that di recti on by
desi gn. I f OK, repai r the ci rcui ts from the motor to
the door modul e or swi tch as requi red. I f not OK,
repl ace the faul ty motor.
(3) I f the motor operates i n both di recti ons, check
the operati on of the wi ndow gl ass and l i ft mechani sm
through i ts compl ete up and down travel . There
shoul d be no bi ndi ng or sti cki ng of the wi ndow gl ass
or l i ft mechani sm through the enti re travel range. I f
not OK, refer to Group 23 - Body to check the wi n-
dow gl ass, tracks, and regul ator for sti cki ng, bi ndi ng,
or i mproper adjustment.
DOOR MODULE
cabl e.
speaker gri l l e.
Fig. 1 Rear Power Window Switch Continuity
U-NUT
FRONT DOOR
U-NUT
POWER WINDOW SWITCH
cabl e.
door power wi ndow swi tch.
(7) Unsnap the swi tch from the receptacl e i n the
tri m panel (Fi g. 5).
POWER WINDOW MOTOR
FRONT DOOR
(2) Remove the watershi el d from the i nner door
panel .
(3) Loosen the two nuts that secure the door gl ass
to the wi ndow regul ator l i ft pl ate (Fi g. 6).
Fig. 5 Rear Door Power Window Switch Remove/
Install
REAR POWER WINDOW SWITCH REAR DOOR TRIM PANEL SWITCH RECEPTACLE
Fig. 6 Glass Attaching Nuts
LOOSEN 2 NUTS SLIDE
(4) Sl i de the door gl ass rearward to remove i t from
the nuts.
(5) Pul l the door gl ass to the ful l up posi ti on and
tape the gl ass to the upper door wi ndow frame.
power wi ndow motor.
(7) Remove the four screws that secure the wi ndow
regul ator to the i nner door panel (Fi g. 7).
(8) Loosen the l ast two screws that secure the reg-
ul ator to the i nner door panel .
(9) Remove the wi ndow regul ator and motor
assembl y from i nsi de the door.
(10) To i nstal l , pl ace the wi ndow regul ator i nsi de
the door and sl i de the two l oose screws i nto the sl ot-
ted hol es i n the door i nner panel .
(11) I nstal l the remai ni ng regul ator mounti ng
screws and ti ghten to 12 Nm (105 i n. l bs.).
(12) Remove the tape used to secure the gl ass to
the upper door wi ndow frame and l ower the gl ass.
Move the gl ass as far rearward i nto the channel as
possi bl e and push down. Ti ghten the two l oose wi n-
dow regul ator screws to 12 Nm (105 i n. l bs.).
(13) Attach the door gl ass by sl i di ng the two nuts
i nto the sl otted hol es on the regul ator l i ft pl ate.
Ti ghten the nuts to 12 Nm (105 i n. l bs.).
(15) Use an adhesi ve/seal ant to i nstal l the pl asti c
watershi el d to the door i nner panel .
REAR DOOR
(1) Remove the rear door tri m panel as descri bed
under Power Wi ndow Swi tch i n thi s group.
(2) Remove the watershi el d from the i nner door
panel .
(3) Loosen the two nuts that secure the door gl ass
to the wi ndow regul ator l i ft pl ate (Fi g. 8).
(4) Sl i de the door gl ass forward to remove i t from
the nuts.
(5) Pul l the door gl ass to the ful l up posi ti on and
tape the gl ass to the upper door wi ndow frame.
(7) Remove the four screws that secure the wi ndow
regul ator to the i nner door panel (Fi g. 9).
(8) Loosen the l ast two screws that secure the reg-
ul ator to the i nner door panel .
(9) Remove the wi ndow regul ator and motor
assembl y from i nsi de the door.
(10) To i nstal l , pl ace the wi ndow regul ator i nsi de
the door and sl i de the two l oose screws i nto the sl ot-
ted hol es i n the door i nner panel .
(11) I nstal l the remai ni ng regul ator mounti ng
screws and ti ghten to 12 Nm (105 i n. l bs.).
(12) Remove the tape used to secure the gl ass to
the upper door wi ndow frame and l ower the gl ass.
Move the gl ass as far rearward i nto the channel as
Fig. 7 Front Door Window Regulator Remove/Install
LOOSEN ONLY CHANNEL ATTACHING SCREWS REGULATOR SCREWS LOOSEN ONLY
Fig. 8 Glass Attaching Nuts
LOOSEN 2 NUTS SLIDE
Fig. 9 Rear Door Window Regulator Remove/Install
LOOSEN
ONLY
LOOSEN ONLY CHANNEL ATTACH- ING SCREW REGULATOR SCREWS
possi bl e and push down. Ti ghten the two l oose wi n-
dow regul ator screws to 12 Nm (105 i n. l bs.).
(13) Attach the door gl ass by sl i di ng the two nuts
i nto the sl otted hol es on the regul ator l i ft pl ate.
Ti ghten the nuts to 12 Nm (105 i n. l bs.).
(15) Use an adhesi ve/seal ant to i nstal l the pl asti c
watershi el d to the door i nner panel .
POWER MIRROR SYSTEMS
CONTENTS
page page
AUTOMATIC DAY/NIGHT MIRROR . . . . . . . . . . . 6 OUTSIDE POWER MIRRORS . . . . . . . . . . . . . . . 1
OUTSIDE POWER MIRRORS
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER MIRROR SWITCH . . . . . . . . . . . . . . . . 2
POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER MIRROR SYSTEM . . . . . . . . . . . . . . . . 2
POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 3
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
INTRODUCTION
Power operated and heated outsi de rear vi ew mi r-
rors are standard factory-i nstal l ed equi pment on thi s
model . Fol l owi ng are general descri pti ons of the
major components i n the power mi rror system.
Refer to 8W-62 - Power Mi rrors i n Group 8W - Wi r-
di agrams. Refer to the owners manual for more
i nformati on on the features and use of thi s system.
MEMORY SYSTEM
mi tter.
recal l .
ZG POWER MIRROR SYSTEMS 8T - 1
procedures for the power mi rror system components.
For di agnosi s of the memory system, use of a DRB
scan tool and the proper Body Di agnosti c Procedures
manual are recommended. For addi ti onal i nformati on
on the features and functi ons of the memory system,
POWER MIRROR
The power mi rrors are connected to battery feed at
al l ti mes. Each mi rror head contai ns two el ectri c
motors, two dri ve mechani sms, an el ectri c heati ng
el ement, hori zontal and verti cal posi ti on sensors for
the memory system opti on, and the mi rror gl ass. One
motor and dri ve control s mi rror up-and-down move-
ment, and the other control s ri ght-and-l eft move-
ment.
An opti onal dri ver si de outsi de el ectrochromi c mi r-
ror i s abl e to automati cal l y change i ts refl ectance
l evel . Thi s mi rror i s control l ed by the ci rcui try of the
automati c day/ni ght i nsi de rear vi ew mi rror. A thi n
l ayer of el ectrochromi c materi al between two pi eces
of conducti ve gl ass make up the face of the mi rror.
Two photocel l sensors on the i nsi de rear vi ew mi rror
are used to moni tor l i ght l evel s and adjust the refl ec-
tance of both the i nsi de and dri ver si de outsi de mi r-
rors. Thi s change i n refl ectance hel ps to reduce the
gl are of headl amps approachi ng the vehi cl e from the
rear. Refer to the Automati c Day/Ni ght Mi rror sec-
ti on of thi s group for more i nformati on on the opera-
ti on of thi s system.
The power mi rror assembl y cannot be repai red.
Onl y the mi rror gl ass and gl ass case are servi ced
separatel y. I f any other component of the power mi r-
ror uni t i s faul ty or damaged, the enti re assembl y
must be repl aced.
POWER MIRROR SWITCH
Both the ri ght and l eft power outsi de mi rrors are
control l ed by a si ngl e mul ti -functi on swi tch uni t
l ocated on the dri ver si de door tri m panel . Thi s
swi tch uni t i s i ntegral to the Dri ver Door Modul e
(DDM).
A sel ector swi tch i s moved ri ght (ri ght mi rror con-
trol ), l eft (l eft mi rror control ), or center to turn the
power outsi de mi rror control off. Then one of four
di recti onal control buttons i s depressed to control
movement of the sel ected mi rror up, down, ri ght, or
l eft.
The power mi rror swi tch cannot be repai red and, i f
faul ty or damaged, the DDM uni t must be repl aced.
DOOR MODULE
bus network.
Each door modul e control s the posi ti oni ng of i ts
respecti ve outsi de mi rror. When the power mi rror
swi tch on the DDM i s used to posi ti on the passenger
si de outsi de mi rror, the DDM sends mi rror posi ti on-
i ng messages to the PDM on the CCD data bus. The
PDM then moves the passenger si de mi rror accord-
i ngl y.
Both the PDM and DDM respond to the defogger
swi tch status messages sent by the Body Control
Modul e (BCM) on the CCD data bus to control the
heater el ements of thei r respecti ve mi rrors. Refer to
Group 8N - El ectri cal l y Heated Systems for more
i nformati on on thi s feature.
On model s equi pped wi th the opti onal memory sys-
tem, each door modul e stores the Dri ver 1 and 2 mi r-
ror posi ti on i nformati on for i ts respecti ve mi rror.
When the DDM recei ves a Dri ver 1 or 2 si gnal from
the Memory Swi tch or from the Remote Keyl ess
Entry (RKE) recei ver i n the PDM, the DDM posi ti ons
the dri ver si de mi rror and sends a memory recal l
message back to the PDM on the CCD data bus to
posi ti on the passenger si de mi rror.
Procedures manual .
POWER MIRROR SYSTEM
I f onl y one power mi rror i s i noperati ve, or parti al l y
i noperati ve, see the tests under Power Mi rror i n thi s
group. I f both power mi rrors are i noperati ve, proceed
as fol l ows. For ci rcui t descri pti ons and di agrams,
refer to 8W-62 - Power Mi rrors i n Group 8W - Wi ri ng
Di agrams.
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose this
system involves the use of a DRB scan tool and the
proper Body Diagnostic Procedures Manual.
8T - 2 POWER MIRROR SYSTEMS ZG
(1) Check the ci rcui t breaker i n the juncti on bl ock.
I f OK, go to Step 2. I f not OK, repl ace the faul ty ci r-
cui t breaker.
(2) Check the fuse i n the Power Di stri buti on Cen-
ter (PDC). I f OK, go to Step 3. I f not OK, repl ace the
faul ty fuse.
cabl e. Remove the dri ver si de door tri m panel as
descri bed i n thi s group. Check the 12-way Dri ver
Door Modul e (DDM) wi re harness connector to see
that i t i s ful l y seated i n the door modul e receptacl e.
I f OK, go to Step 4. I f not OK, i nstal l the wi re har-
ness connector properl y.
(4) Unpl ug the 12-way wi re harness connector
from the DDM. Check for conti nui ty between the
ground ci rcui t cavi ty of the DDM wi re harness con-
nector and a good ground. There shoul d be conti nu-
i ty. I f OK, go to Step 5. I f not OK, repai r the open
DDM wi re harness connector. I f OK, use a DRB scan
tool and the proper Body Di agnosti c Procedures man-
ual to test both door modul es and the CCD data bus.
I f not OK, repai r the open ci rcui t as requi red.
POWER MIRROR
I f both power mi rrors are i noperati ve, see the tests
under Power Mi rror System i n thi s group. I f onl y one
power mi rror i s i noperati ve, or parti al l y i noperati ve,
refer to the symptom di agnosi s as fol l ows. For ci rcui t
descri pti ons and di agrams, refer to 8W-62 - Power
Mi rrors i n Group 8W - Wi ri ng Di agrams.
LIMITED OR NO MIRROR MOVEMENT
cabl e. Remove the front door tri m panel on the si de
of the i noperati ve mi rror as descri bed under Door
(2) Unpl ug the mi rror wi re harness connector from
the door modul e. Usi ng two jumper wi res, test the
mi rror as shown i n the Mi rror Test chart (Fi g. 1). I f
the mi rror tests OK, use a DRB scan tool and the
proper Body Di agnosti c Procedures manual to test
the door modul e and the CCD data bus. I f the mi rror
does not test OK, repl ace the faul ty mi rror.
NO MIRROR HEAT
I f both mi rror heaters are i noperati ve, refer to
Group 8N - El ectri cal l y Heated Systems to test the
Rear Defogger System.
cabl e. Remove the front door tri m panel on the si de
of the i noperati ve mi rror as descri bed under Door
(2) Unpl ug the mi rror wi re harness connector from
the door modul e. Check for conti nui ty between the
heater swi tched ground ci rcui t cavi ty and the heater
12V suppl y ci rcui t cavi ty of the mi rror wi re harness
connector. There shoul d be conti nui ty. I f OK, use a
cedures manual to test the door modul e and the CCD
data bus. I f not OK, repl ace the faul ty mi rror.
NO MIRROR DIMMING (Driver Side Only)
(1) Test the operati on of the Automati c Day/Ni ght
Mi rror as descri bed i n thi s group. I f OK, go to Step
2. I f not OK, repai r the automati c day/ni ght mi rror
uni t as necessary before you proceed.
cabl e. Remove the dri ver si de front door tri m panel
as descri bed under Door Modul e i n thi s group.
(3) Unpl ug the 2-way el ectrochromi c mi rror wi re
harness connector from the dri ver si de outsi de mi rror
and connect a vol tmeter to the door wi re harness hal f
of the connector. Perform the automati c day/ni ght
mi rror test as descri bed i n thi s group, whi l e observ-
i ng the vol tmeter. A vol tmeter readi ng of 1.45 0.05
vol ts i ndi cates a proper di mmi ng si gnal i s bei ng
recei ved at the mi rror wi re harness connector. I f OK,
POWER MIRROR HARNESS CONNECTOR
APPLY 12
VOLTS TO:
APPLY
GROUND TO:
MIRROR
REACTION
A G LEFT
G A RIGHT
H G UP
G H DOWN
Fig. 1 Mirror Test
repl ace the faul ty power mi rror. I f not OK, repai r the
ci rcui ts to the automati c day/ni ght mi rror as
requi red.
NO MIRROR MEMORY
For di agnosi s of the memory system, the use of a
cedures manual are recommended.
DOOR MODULE
cabl e.
speaker gri l l e.
U-NUT FRONT DOOR U-NUT PLUG BEZEL TRIM PANEL FWD
POWER MIRROR
cabl e.
(3) Unpl ug the el ectrochromi c mi rror wi re harness
connector, i f equi pped.
(4) Uncl i p the mi rror wi re harness(es) from the
i nner door panel .
(5) Remove the mi rror fl ag seal (Fi g. 4).
(6) Remove the three nuts that secure the mi rror
to the door.
(7) Remove the mi rror from the door.
Ti ghten the mi rror mounti ng nuts to 7.4 Nm (65 i n.
l bs.).
Fig. 4 Power Mirror Remove/Install
AUTOMATIC DAY/NIGHT MIRROR
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 6
AUTOMATIC DAY/NIGHT MIRROR . . . . . . . . . . . 6
GENERAL INFORMATION
INTRODUCTION
An automati c di mmi ng i nsi de day/ni ght rear vi ew
mi rror and an automati c di mmi ng dri ver si de outsi de
rear vi ew mi rror are avai l abl e factory-i nstal l ed
opti ons on thi s model . Fol l owi ng i s a general descri p-
ti on of thi s opti onal equi pment. Refer to 8W-44 -
I nteri or Li ghti ng and 8W-62 - Power Mi rrors i n
The automati c day/ni ght mi rror i s abl e to automat-
i cal l y change i ts refl ectance. A thi n l ayer of el ectro-
chromi c materi al between two pi eces of conducti ve
gl ass make up the face of the mi rror. Two photocel l
sensors are used to moni tor l i ght l evel s and adjust
the refl ectance of the mi rror to reduce the gl are of
headl amps approachi ng the vehi cl e from the rear.
The ambi ent photocel l sensor faces forward, to
detect the outsi de l i ght l evel s. The headl amp sensor
faces rearward, to detect the l i ght l evel recei ved at
the rear wi ndow si de of the mi rror. When the di ffer-
ence between the two l i ght l evel s becomes too great
(the l i ght l evel recei ved at the rear of the mi rror i s
much hi gher than at the front of the mi rror), the
mi rror begi ns to darken.
The mi rror swi tch al l ows the dri ver a manual con-
trol of whether the automati c di mmi ng feature i s
operati onal . When On i s sel ected, the mi rror swi tch
i s l i ghted by an i ntegral Li ght-Emi tti ng Di ode (LED).
The automati c di mmi ng feature wi l l onl y operate
when the i gni ti on swi tch i s i n the On posi ti on. The
mi rror al so senses the backup l amp ci rcui t, and di s-
abl es the sel f-di mmi ng feature whenever the trans-
mi ssi on gear sel ector i s i n the Reverse posi ti on.
On model s wi th an opti onal el ectrochromi c dri ver
si de outsi de rear vi ew mi rror, the si gnal to control
the di mmi ng of that mi rror i s generated by the auto-
mati c day/ni ght i nsi de rear vi ew mi rror ci rcui try.
That si gnal i s then del i vered to the dri ver si de out-
si de rear vi ew mi rror on a hard-wi red ci rcui t.
The automati c day/ni ght mi rror cannot be
repai red. I f faul ty or damaged, the enti re i nsi de rear
vi ew mi rror assembl y must be repl aced.
8W-44 - I nteri or Li ghti ng or 8W-62 Power Mi rrors i n
Check for battery vol tage at the fuse i n the juncti on
mi rror (Fi g. 1). Check for battery vol tage at the fused
i gni ti on swi tch output ci rcui t cavi ty of the mi rror
wi re harness connector. I f OK, go to Step 4. I f not
OK, repai r the open ci rcui t to the juncti on bl ock as
requi red.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the mi rror wi re harness connector and a good
5. I f not OK, repai r the ci rcui t to ground as requi red.
(5) Turn the i gni ti on swi tch to the On posi ti on. Set
the parki ng brake. Pl ace the transmi ssi on gear sel ec-
tor l ever i n the Reverse posi ti on. Check for battery
vol tage at the backup l amp swi tch output ci rcui t cav-
i ty of the mi rror wi re harness connector. I f OK, pl ug
i n the mi rror wi re harness connector and go to Step
(6) Pl ace the transmi ssi on gear sel ector l ever i n
the Neutral posi ti on. Pl ace the mi rror swi tch i n the
On (LED i n the swi tch i s l i ghted) posi ti on. Cover the
forward faci ng ambi ent photocel l sensor to keep out
any ambi ent l i ght.
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7) Shi ne a l i ght i nto the rearward faci ng head-
l amp photocel l sensor. The mi rror shoul d darken. I f
OK, go to Step 8. I f not OK, repl ace the faul ty mi rror
uni t.
(8) Wi th the mi rror darkened, pl ace the transmi s-
si on gear sel ector l ever i n the Reverse posi ti on. The
mi rror shoul d return to i ts normal refl ectance. I f not
OK, repl ace the faul ty mi rror uni t.
cabl e.
(2) I f so equi pped, remove the wi re harness cover
by graspi ng the l ower porti on of the cover and sl i di ng
i t i nto the upper porti on and off of the mi rror base
(Fi g. 2).
mi rror.
(4) Remove the set screw that secures the mi rror
to the wi ndshi el d support button.
(5) Push the mi rror up far enough to cl ear the sup-
port button and remove the mi rror.
Fig. 1 Automatic Day/Night Mirror
REAR FACING SENSOR CONNECTOR FORWARD FACING SENSOR SWITCH
Fig. 2 Automatic Day/Night Mirror Remove/Install-
Typical
RELEASE TAB ELECTRICAL CONNECTOR ON/OFF SWITCH
CHIME/BUZZER WARNING SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
DRIVER DOOR AJAR SWITCH . . . . . . . . . . . . . 2
DRIVER SEAT BELT SWITCH . . . . . . . . . . . . . . 2
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2
KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . . . . 2
DRIVER DOOR AJAR SWITCH . . . . . . . . . . . . . 2
DRIVER SEAT BELT SWITCH . . . . . . . . . . . . . . 3
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 3
KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . . . . 3
CHIME WARNING SYSTEM SWITCHES . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
Thi s group covers the chi me warni ng system,
whi ch i s standard factory-i nstal l ed equi pment on thi s
model . The chi me warni ng system provi des an audi -
bl e warni ng to the dri ver under the fol l owi ng condi -
ti ons:
A door i s ajar above a cri ti cal speed [about 16
ki l ometers-per-hour (10 mi l es-per-hour) for the dri ver
si de front door, or about 5 ki l ometers-per-hour (3
mi l es-per-hour) for any other door]
Check engi ne l amp i l l umi nati on
Check gauges l amp i l l umi nati on
Dri ver si de seat bel t i s not fastened (bel t web-
bi ng i s on the retractor spool ) wi th the i gni ti on
swi tch i n the On posi ti on
Head or park l amps are turned on wi th the i gni -
ti on swi tch Off and the dri ver si de front door open
Hi gh speed warni ng - Gul f Coast Countri es
(export onl y)
Key i s i n the i gni ti on swi tch wi th the i gni ti on
swi tch Off and the dri ver si de front door open
Low fuel warni ng l amp i l l umi nati on - l ess than
about one-ei ghth tank of fuel remai ni ng
Rear l amp fai l ure
Transmi ssi on oi l temperature i s too hi gh
Turn si gnal remai ns on for about 1.6 ki l ometers
(one mi l e) wi th no decrease i n speed or throttl e open-
i ng
Washer l evel l ow l amp i l l umi nati on.
components i n the chi me warni ng system. Refer to
8W-44 - I nteri or Li ghti ng or 8W-45 - Body Control
Modul e i n Group 8W - Wi ri ng Di agrams for compl ete
BODY CONTROL MODULE
supports i s the chi me warni ng system. The BCM con-
tai ns a chi me tone generator to perform the functi ons
of the chi me warni ng modul e. The BCM uses hard-
wi red i nputs, i nternal programmi ng, and CCD data
bus chi me request message i nputs to deci de when a
chi me tone i s requi red.
cedures.
ZG CHIME/BUZZER WARNING SYSTEMS 8U - 1
Thi s group onl y covers the di agnosi s and servi ce of
the hard-wi red i nputs used by the BCM to determi ne
that a chi me tone shoul d be generated. For di agnosi s
of the BCM, the CCD data bus, or the other el ec-
troni c modul es on the CCD data bus that send chi me
request messages to the BCM, refer to the proper
Body Di agnosti c Procedures manual . The BCM can
onl y be servi ced by an authori zed el ectroni c repai r
stati on. Refer to the l atest Warranty Pol i ci es and
Procedures manual for a current l i sti ng of authori zed
repai r stati ons.
DRIVER DOOR AJAR SWITCH
The dri ver door ajar swi tch i s mounted to the
dri ver si de front door l atch pi l l ar. The swi tch cl oses a
path to ground for the Body Control Modul e (BCM)
dri ver front door ajar swi tch ci rcui t when the dri ver
door i s opened, and opens the ground path when the
dri ver door i s cl osed.
The dri ver door ajar swi tch cannot be repai red
and, i f faul ty or damaged, i t must be repl aced. Refer
to Group 8Q - Vehi cl e Theft/Securi ty Systems for the
DRIVER SEAT BELT SWITCH
The dri ver seat bel t swi tch i s i ntegral to the dri ver
seat bel t ti p-hal f retractor assembl y. The swi tch i s
normal l y cl osed, provi di ng a ground path to the Body
Control Modul e (BCM) through the seat bel t swi tch
sense ci rcui t. The swi tch moni tors the amount of seat
bel t webbi ng wound onto the seat bel t retractor
spool . When the seat bel t ti p-hal f webbi ng i s pul l ed
out of the retractor far enough to engage the seat
bel t buckl e-hal f, the swi tch opens the ground path.
The dri ver seat bel t swi tch cannot be repai red and,
i f faul ty or damaged, the enti re dri ver seat bel t ti p-
hal f and retractor uni t must be repl aced. Refer to
Group 23 - Body for the servi ce procedures.
KEY-IN IGNITION SWITCH
The key-i n i gni ti on swi tch i s i ntegral to the i gni -
ti on swi tch, whi ch i s mounted on the ri ght si de of the
steeri ng col umn. I t cl oses a path to ground for the
Body Control Modul e (BCM) when the i gni ti on key i s
i nserted i n the i gni ti on l ock cyl i nder. The key-i n i gni -
ti on swi tch opens the ground path when the key i s
removed from the i gni ti on l ock cyl i nder.
The key-i n i gni ti on swi tch cannot be repai red and,
i f faul ty or damaged, the enti re i gni ti on swi tch must
be repl aced. Refer to Group 8D - I gni ti on Systems for
the servi ce procedures.
HEADLAMP SWITCH
The headl amp swi tch i s i ntegral to the outboard
swi tch pod l ocated i n the i nstrument panel , outboard
of the steeri ng col umn. I t provi des a battery vol tage
si gnal to the Body Control Modul e (BCM) park l amp
rel ay output ci rcui t when the park or head l amps are
turned on. The headl amp swi tch opens the park l amp
rel ay output ci rcui t when the headl amp swi tch i s
turned off.
The headl amp swi tch cannot be repai red and, i f
faul ty or damaged, the outboard swi tch pod uni t
must be repl aced. Refer to Group 8E - I nstrument
Panel Systems for the servi ce procedures.
DRIVER DOOR AJAR SWITCH
8W-45 - Body Control Modul e i n Group 8W - Wi ri ng
Di agrams.
INJURY.
(1) Open the dri ver si de front door and note
whether the i nteri or l amps l i ght. They shoul d l i ght.
I f OK, see the di agnosi s for the Key-I n I gni ti on
Swi tch or the Headl amp Swi tch i n thi s group. I f not
OK, go to Step 2.
cabl e. Unpl ug the dri ver door ajar swi tch from i ts
the swi tch termi nal and the swi tch body. There
shoul d be conti nui ty wi th the swi tch pl unger
rel eased, and no conti nui ty wi th the swi tch pl unger
depressed. I f OK, go to Step 3. I f not OK, repl ace the
faul ty swi tch.
(3) Unpl ug the bl ack 14-way wi re harness connec-
conti nui ty between the dri ver door ajar swi tch wi re
harness connector and a good ground. There shoul d
(4) Check for conti nui ty between the dri ver si de
front door ajar swi tch sense ci rcui t cavi ti es of the
dri ver door ajar swi tch wi re harness connector and
the bl ack 14-way BCM wi re harness connector. There
shoul d be conti nui ty. I f OK, use a DRB scan tool and
the proper Di agnosti c Procedures manual to test the
BCM. I f not OK, repai r the open ci rcui t as requi red.
8U - 2 CHIME/BUZZER WARNING SYSTEMS ZG
DRIVER SEAT BELT SWITCH
8W-45 - Body Control Modul e i n Group 8W - Wi ri ng
Di agrams.
INJURY.
cabl e. Unpl ug the dri ver seat bel t swi tch wi re har-
ness connector from the dri ver seat bel t retractor
behi nd the B pi l l ar tri m. Check for conti nui ty
between the seat bel t swi tch sense ci rcui t and the
ground ci rcui t cavi ti es of the seat bel t retractor hal f
of the dri ver seat bel t swi tch wi re harness connector.
There shoul d be conti nui ty wi th the seat bel t web-
bi ng retracted, and no conti nui ty wi th the seat bel t
webbi ng extracted far enough to buckl e the seat bel t.
I f OK, go to Step 2. I f not OK, repl ace the faul ty seat
bel t ti p-hal f and retractor assembl y.
cui t cavi ty i n the body hal f of the dri ver seat bel t
swi tch wi re harness connector and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 3. I f not
OK, repai r the ci rcui t to ground as requi red.
conti nui ty between the seat bel t swi tch sense ci rcui t
cavi ty i n the body hal f of the dri ver seat bel t swi tch
shoul d be no conti nui ty. I f OK, go to Step 4. I f not
OK, repai r the short ci rcui t as requi red.
(4) Check for conti nui ty between the seat bel t
swi tch sense ci rcui t cavi ti es i n the body hal f of the
dri ver seat bel t swi tch wi re harness connector and
the 14-way BCM wi re harness connector. There
shoul d be conti nui ty. I f OK, use a DRB scan tool and
the proper Di agnosti c Procedures manual to test the
KEY-IN IGNITION SWITCH
8W-40 - I nstrument Cl uster or 8W-44 - I nteri or
INJURY.
cabl e. Remove the steeri ng col umn shrouds. Refer to
Group 8D - I gni ti on Systems for the procedures.
Unpl ug the key-i n i gni ti on swi tch wi re harness con-
nector from the i gni ti on swi tch.
(2) Check for conti nui ty between the key-i n i gni -
ti on swi tch sense and ground termi nal s of the key-i n
i gni ti on swi tch. There shoul d be conti nui ty wi th the
key i n the i gni ti on l ock cyl i nder, and no conti nui ty
wi th the key removed from the i gni ti on l ock cyl i nder.
I f OK, go to Step 3. I f not OK, repl ace the faul ty i gni -
ti on swi tch assembl y.
cui t cavi ty of the key-i n i gni ti on swi tch wi re harness
tor from the Body Control Modul e (BCM). Refer to
dures. Check for conti nui ty between the key-i n i gni -
ti on swi tch sense ci rcui t cavi ty of the key-i n i gni ti on
swi tch wi re harness connector and a good ground.
(5) Check for conti nui ty between the key-i n i gni -
ti on swi tch sense ci rcui t cavi ti es of the key-i n i gni -
ti on swi tch wi re harness connector and the bl ack
24-way BCM wi re harness connector. There shoul d
be conti nui ty. I f OK, use a DRB scan tool and the
proper Di agnosti c Procedures manual to test the
HEADLAMP SWITCH
I f the park l amps are i noperati ve, refer to Group
8L - Lamps for di agnosi s. I f the park l amps operate,
but there i s no chi me warni ng i ssued wi th the dri ver
si de front door open, proceed as fol l ows. For ci rcui t
ment Cl uster or 8W-44 - I nteri or Li ghti ng i n Group
INJURY.
ZG CHIME/BUZZER WARNING SYSTEMS 8U - 3
cabl e. Remove the outboard swi tch pod from the
i nstrument panel . Refer to Group 8E - I nstrument
Panel Systems for the procedures. Unpl ug the head-
l amp swi tch wi re harness connector. Unpl ug the
bl ack 24-way wi re harness connector from the Body
Control Modul e (BCM). Check for conti nui ty between
the park l amp rel ay output ci rcui t cavi ty of the head-
l amp swi tch wi re harness connector and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 2. I f not OK, repai r the short ci rcui t as
requi red.
(2) Check for conti nui ty between the park l amp
rel ay output ci rcui t cavi ti es of the headl amp swi tch
wi re harness connector and the bl ack 24-way BCM
wi re harness connector. There shoul d be conti nui ty. I f
OK, use a DRB scan tool and the proper Di agnosti c
Procedures manual to test the BCM. I f not OK,
CHIME WARNING SYSTEM SWITCHES
Servi ce procedures for the vari ous hard-wi red
swi tches used i n the chi me warni ng system can be
found i n the appropri ate group as fol l ows:
Dri ver door ajar swi tch - refer to Group 8Q -
Vehi cl e Theft/Securi ty Systems
Dri ver seat bel t swi tch - refer to Group 23 -
Body
Headl amp swi tch - refer to Group 8E - I nstru-
ment Panel Systems
Key-i n i gni ti on swi tch - refer to Group 8D - I gni -
ti on Systems.
8U - 4 CHIME/BUZZER WARNING SYSTEMS ZG
OVERHEAD CONSOLE SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
COMPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GARAGE DOOR OPENER STORAGE BIN . . . . . 2
READING AND COURTESY LAMP . . . . . . . . . . . 2
SUNGLASSES STORAGE BIN . . . . . . . . . . . . . . 3
THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . 2
TRIP COMPUTER . . . . . . . . . . . . . . . . . . . . . . . 1
THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . 3
TRIP COMPUTER, COMPASS, AND
THERMOMETER DISPLAY MODULE . . . . . . . 3
SERVICE PROCEDURES
COMPASS CALIBRATION . . . . . . . . . . . . . . . . . 4
COMPASS DEMAGNETIZING . . . . . . . . . . . . . . 5
COMPASS VARIATION ADJUSTMENT . . . . . . . . 4
AMBIENT TEMPERATURE SENSOR . . . . . . . . . 8
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . 6
PUSH BUTTON MODULE . . . . . . . . . . . . . . . . . 7
READING AND COURTESY LAMP BULB . . . . . . 7
THERMOMETER DISPLAY MODULE . . . . . . . 7
GENERAL INFORMATION
INTRODUCTION
Two overhead consol es featuri ng a mi ni tri p com-
puter, an el ectroni c compass, and an outsi de ambi ent
temperature thermometer are avai l abl e factory-i n-
stal l ed opti ons on thi s model . A l ong versi on of the
overhead consol e i s used on model s wi thout a power
sunroof opti on. A short versi on of the overhead con-
sol e i s used on model s wi th a power sunroof opti on.
The l ong overhead consol e al so i ncl udes two front-
mounted and two rear-mounted readi ng and courtesy
l amps, a garage door opener storage bi n, and a sun-
gl asses storage bi n. The short overhead consol e al so
i ncl udes two readi ng and courtesy l amps and houses
the power sunroof swi tch.
components used i n the overhead consol e. Refer to
8W-49 - Overhead Consol e i n Group 8W - Wi ri ng
grams.
TRIP COMPUTER
A mi ni tri p computer i s avai l abl e on thi s model to
provi de several el ectroni c functi ons and features. The
tri p computer contai ns a central processi ng uni t and
i nterfaces wi th other modul es i n the vehi cl e on the
Some of the functi ons and features that the tri p
computer supports and/or control s, i ncl ude the fol -
l owi ng di spl ay opti ons:
Compass and temperature
Tri p odometer (ODO)
Average fuel economy (AVG ECO)
I nstant fuel economy (ECO)
Di stance to empty (DTE)
El apsed ti me (ET)
Bl ank di spl ay.
Momentari l y depressi ng and rel easi ng the Step
button when the i gni ti on swi tch i s i n the On posi ti on
wi l l cause the overhead consol e di spl ay to step
sequenti al l y through the l i sted di spl ay opti ons.
Momentari l y depressi ng and rel easi ng the U.S./Met-
ri c button toggl es the di spl ay between U.S. and Met-
ri c measurements. For more i nformati on on the tri p
computer features and functi ons, refer to the owners
manual i n the vehi cl e gl ove box.
ZG OVERHEAD CONSOLE SYSTEMS 8V - 1
The push button (Step and U.S./Metri c) swi tch
modul e i n the overhead consol e i s hard-wi red to the
tri p computer. The compass fl ux-gate uni t i s i ntegral
to the tri p computer, compass, and thermometer di s-
pl ay modul e uni t. Data i nput for al l other tri p com-
puter functi ons i s recei ved through CCD data bus
messages. The tri p computer uses i ts i nternal pro-
grammi ng and al l of these i nputs to cal cul ate and
di spl ay the requested data. I f the data di spl ayed i s
i ncorrect, perform the sel f-di agnosti c tests as
descri bed i n thi s group. I f these tests prove i nconcl u-
si ve, the use of a DRB scan tool and the proper Body
Di agnosti c Procedures manual are recommended for
further testi ng of the tri p computer and the CCD
data bus.
The tri p computer, compass, and thermometer di s-
pl ay modul e cannot be repai red, and are onl y avai l -
abl e for servi ce as a uni t. I f faul ty, the compl ete
modul e must be repl aced. The push button (Step and
U.S./Metri c) swi tch modul e i s servi ced separatel y.
COMPASS
The compass wi l l di spl ay the di recti on i n whi ch the
vehi cl e i s poi nted usi ng the ei ght major compass
headi ngs (Exampl es: north i s N, northeast i s NE). I t
does not di spl ay the headi ngs i n actual degrees.
The sel f-cal i brati ng compass uni t requi res no
adjusti ng i n normal use. The onl y cal i brati on that
may prove necessary i s to dri ve the vehi cl e i n three
compl ete ci rcl es, on l evel ground, i n not l ess than 48
seconds. Thi s wi l l reori ent the compass uni t to i ts
vehi cl e.
The compass uni t al so wi l l compensate for magne-
ti sm the body of the vehi cl e may acqui re duri ng nor-
mal use. However, avoi d pl aci ng anythi ng magneti c
di rectl y on the roof of the vehi cl e. Magneti c mounts
for an antenna, a repai r order hat, or a funeral pro-
cessi on fl ag can exceed the compensati ng abi l i ty of
the compass uni t i f pl aced on the roof panel . Mag-
neti c bi t dri vers used on the fasteners that hol d the
assembl y to the roof header can al so affect compass
operati on. I f the vehi cl e roof shoul d become magne-
ti zed, the demagneti zi ng and cal i brati on procedures
found i n thi s group may be requi red to restore proper
compass operati on.
The compass, tri p computer, and thermometer di s-
U.S./Metri c) swi tch modul e i s servi ced separatel y.
THERMOMETER
The thermometer di spl ays the outsi de ambi ent
temperature. The temperature di spl ay can be
changed from Fahrenhei t to Cel si us usi ng the U.S./
Metri c button, l ocated just rearward of the di spl ay
modul e. The di spl ayed temperature i s not an i nstant
readi ng of condi ti ons, but an average temperature. I t
may take the thermometer di spl ay several mi nutes
to respond to a major temperature change, such as
dri vi ng out of a heated garage i nto wi nter tempera-
tures.
When the i gni ti on swi tch i s turned to the Off posi -
ti on, the l ast di spl ayed temperature readi ng stays i n
the thermometer uni t memory. When the i gni ti on
swi tch i s turned to the On posi ti on agai n, the ther-
mometer wi l l di spl ay the memory temperature for
one mi nute; then update the di spl ay to the current
average temperature readi ng wi thi n fi ve mi nutes.
When the outsi de temperature i s bel ow 3 C (37
F), the thermometer wi l l provi de an i ce i ndi cator
functi on to al ert the dri ver of possi bl e i cy road condi -
ti ons. The i ce i ndi cator functi on wi l l cause the word
I CE to be fl ashed on the overhead consol e di spl ay
for approxi matel y two mi nutes. The i ce i ndi cator
functi on wi l l occur onl y one ti me duri ng any i gni ti on
swi tch cycl e. The i ce i ndi cator functi on wi l l not occur
i f the di spl ay i s i n the el apsed ti me mode due to the
character l i mi tati ons of the el apsed ti me di spl ay.
The thermometer functi on i s supported by an
ambi ent temperature sensor. The sensor i s mounted
outsi de the passenger compartment near the front
and center of the vehi cl e and i s hard-wi red to the
Body Control Modul e (BCM). The BCM sends a tem-
perature status message to the overhead consol e over
the CCD data bus network. The ambi ent tempera-
ture sensor i s avai l abl e as a separate servi ce i tem.
The thermometer, compass, and tri p computer di s-
U.S./Metri c) swi tch modul e and ambi ent temperature
sensor are servi ced separatel y.
READING AND COURTESY LAMP
Al l readi ng and courtesy l amps l ocated i n the over-
head consol e are acti vated by the door ajar swi tches.
When the doors are cl osed, the l amps can be i ndi vi d-
ual l y acti vated by depressi ng the correspondi ng l ens.
When a door i s open, depressi ng the l amp l ens
swi tches wi l l not turn the l amps off. Refer to Group
8L - Lamps, for di agnosi s and servi ce of the readi ng
and courtesy l amps.
GARAGE DOOR OPENER STORAGE BIN
A compartment i n the l ong-type overhead consol e
i s desi gned to hol d most garage door opener remote
control transmi tters. The transmi tter i s mounted
wi thi n the compartment wi th an adhesi ve-backed
hook and l oop fastener patch.
Wi th the transmi tter mounted i n the storage bi n,
adapter pegs l ocated on the front of the storage bi n
8V - 2 OVERHEAD CONSOLE SYSTEMS ZG
door are sel ected and mounted on a post i n the cen-
ter of the storage bi n door. The peg(s) sel ected and/or
the post must be l ong enough to depress the button
of the transmi tter, when the garage door opener stor-
age bi n door i s depressed. The pegs may be stacked,
i f necessary. Refer to the owners manual i n the vehi -
cl e gl ove box for more i nformati on.
SUNGLASSES STORAGE BIN
A sungl asses storage bi n i s i ncl uded i n the l ong-
type overhead consol e. The i nteri or of the bi n i s cov-
ered wi th a fl ocki ng materi al to protect the
sungl asses from bei ng scratched. Thi s bi n features a
push/push-type l atchi ng mechani sm, and a vi scous
dampeni ng system for a fl ui d openi ng acti on.
THERMOMETER DISPLAY MODULE
I f the probl em wi th the tri p computer, compass,
and thermometer di spl ay modul e i s an i naccurate or
scrambl ed di spl ay, use the Sel f-Di agnosti c Test proce-
dures. I f the probl em i s a no-di spl ay condi ti on, use
the fol l owi ng procedures. For ci rcui t descri pti ons and
di agrams, refer to 8W-49 - Overhead Consol e i n
(1) Check the fuses i n the juncti on bl ock. I f OK, go
to Step 2. I f not OK, repl ace the faul ty fuse(s).
(2) Remove the overhead consol e as descri bed i n
thi s group. Check for conti nui ty between the ground
ci rcui t cavi ty of the overhead consol e wi re harness
(3) Check for battery vol tage at the fused B(+) ci r-
cui t cavi ty of the overhead consol e wi re harness con-
nector. I f OK, go to Step 4. I f not OK, repai r the open
output ci rcui t cavi ty of the overhead consol e wi re
harness connector. 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) Check for conti nui ty between the courtesy l amp
rel ay output ci rcui t cavi ti es of the overhead consol e
wi re harness connector and the juncti on bl ock recep-
tacl e for the courtesy l amp rel ay. There shoul d be
conti nui ty. I f OK, proceed to the Sel f-Di agnosti c Test
i n thi s group for further di agnosi s of the modul e and
the CCD data bus. I f not OK, repai r the open ci rcui t
to the courtesy l amp rel ay as requi red.
SELF-DIAGNOSTIC TEST
A sel f-di agnosti c test i s used to determi ne that the
tri p computer, compass, thermometer, and al l of the
di spl ay modul e segments are operati ng properl y el ec-
tri cal l y. I ni ti ate the sel f-di agnosti c test as fol l ows:
(1) Wi th the i gni ti on swi tch i n the Off posi ti on,
si mul taneousl y press and hol d the Step button and
the U.S./Metri c button.
(3) Conti nue to hol d both buttons unti l the di spl ay
modul e performs a di spl ay segment test. I n thi s test,
al l of the vacuum fl uorescent di spl ay segments are
l i ghted. Thi s test wi l l :
a. Veri fy that al l di spl ay segments are functi onal
b. Check the i nternal ci rcui try of the modul e
c. Check that al l of the CCD data bus messages
needed are bei ng recei ved.
(4) Respond to the respecti ve test resul ts as fol -
l ows. I f al l tests are passed, the modul e wi l l automat-
i cal l y return to normal operati on.
d. I n the di spl ay segment test, i f any segment
shoul d fai l to l i ght the uni t i s faul ty and must be
repl aced.
e. I f the i nternal ci rcui try test i s fai l ed, the modul e
wi l l di spl ay FAI L. I f FAI L i s di spl ayed, the uni t i s
faul ty and must be repl aced.
f. I f the CCD data bus message test i s fai l ed, the
modul e wi l l di spl ay CCD. I f CCD i s di spl ayed, the
use of a DRB scan tool and the proper Body Di agnos-
ti c Procedures manual are requi red for further di ag-
nosi s.
(5) Momentari l y depress and rel ease ei ther button
one ti me to exi t the sel f-di agnosti c test mode and
return the tri p computer, compass, and thermometer
di spl ay modul e to normal operati on.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earths mag-
netic field strength, based on geographic location.
See the Compass Variation Adjustment procedures,
in this group.
NOTE: If the compass reading has blanked out, and
only CAL appears in the display module, demag-
netizing may be necessary to remove excessive
residual magnetic fields from the vehicle. See the
Compass Demagnetizing procedure, in this group.
THERMOMETER
The thermometer functi on i s supported by a ambi -
ent temperature sensor, a wi ri ng ci rcui t, the Body
Control Modul e (BCM), the CCD data bus, and a por-
ti on of the overhead consol e tri p computer, compass,
and thermometer di spl ay modul e di spl ay. The sensor
i s mounted outsi de the passenger compartment near
the front and center of the vehi cl e.
I f any porti on of the ambi ent temperature sensor
ci rcui t fai l s, the thermometer di spl ay wi l l sel f-di ag-
nose the ci rcui t. An SC (short ci rcui t) wi l l appear i n
the di spl ay i n pl ace of the temperature, when the
sensor i s exposed to temperatures above 55 C (131
F), or i f the sensor ci rcui t i s shorted. An OC (open
ci rcui t) wi l l appear i n the di spl ay i n pl ace of the tem-
perature, when the sensor i s exposed to temperatures
bel ow -40 C (-40 F), or i f the sensor ci rcui t i s open.
The ambi ent temperature sensor ci rcui t can al so be
di agnosed usi ng the fol l owi ng Sensor Test, and Sen-
sor Ci rcui t Test. I f the temperature sensor and ci r-
cui t are confi rmed to be OK, but the temperature
di spl ay i s i noperati ve or i ncorrect, see the Tri p Com-
puter, Compass, and Thermometer Di spl ay Modul e
di agnosi s i n thi s group. For ci rcui t descri pti ons and
di agrams, refer to 8W-45 - Body Control Modul e and
8W-49 - Overhead Consol e i n Group 8W - Wi ri ng
Di agrams.
SENSOR TEST
Unpl ug the temperature sensor wi re harness connec-
tor.
(2) Measure the resi stance of the temperature sen-
sor. At -40 C (-40 F), the sensor resi stance i s 336
ki l ohms. At 55 C (140 F), the sensor resi stance i s
2.488 ki l ohms. The sensor resi stance shoul d read
between these two val ues. I f OK, go to the Sensor
Ci rcui t Test. I f not OK, repl ace the faul ty sensor.
SENSOR CIRCUIT TEST
Unpl ug the ambi ent temperature sensor wi re har-
ness connector and the bl ack 24-way Body Control
Modul e (BCM) wi re harness connector.
(2) Connect a jumper wi re between the two termi -
nal s i n the body hal f of the sensor wi re harness con-
nector.
(3) Check for conti nui ty between the sensor return
ci rcui t and the ambi ent temperature sensor si gnal
ci rcui t cavi ti es of the bl ack 24-way BCM wi re har-
ness connector. There shoul d be conti nui ty. I f OK, go
requi red.
(4) Remove the jumper wi re from the ambi ent tem-
perature sensor wi re harness connector. Check for
conti nui ty between the sensor return ci rcui t cavi ty of
the bl ack 24-way BCM wi re harness connector and a
good ground. There shoul d be no conti nui ty. I f OK, go
to Step 5. I f not OK, repai r the short ci rcui t as
requi red.
(5) Check for conti nui ty between the ambi ent tem-
perature sensor si gnal ci rcui t cavi ty of the bl ack
24-way BCM wi re harness connector and a good
ground. There shoul d be no conti nui ty. I f OK, see the
Tri p Computer, Compass, and Thermometer Di spl ay
Modul e di agnosi s i n thi s group. I f not OK, repai r the
short ci rcui t as requi red.
SERVICE PROCEDURES
COMPASS VARIATION ADJUSTMENT
Vari ance i s the di fference between magneti c north
and geographi c north. I n some geographi c l ocati ons,
the di fference between magneti c and geographi c
north i s great enough to cause the compass to gi ve
fal se readi ngs. I f thi s probl em occurs, the compass
vari ance must be set.
To set the compass vari ance:
(1) Usi ng the Vari ance Setti ngs map, fi nd your
geographi c l ocati on and note the zone number (Fi g.
1).
(2) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/temperature data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the Step
button to step through the di spl ay opti ons unti l you
have reached the compass/temperature di spl ay.
(3) Depress both the U.S./Metri c, and the Step but-
tons. Hol d the buttons down unti l VAR appears i n
the di spl ay. Thi s takes about fi ve seconds.
(4) Rel ease both of the buttons. The current vari -
ance zone number setti ng wi l l appear i n the di spl ay.
(5) Press and rel ease the U.S./Metri c button to
step through the zone numbers, unti l the zone num-
ber for your geographi c l ocati on appears i n the di s-
pl ay.
(6) Press the Step button to enter thi s zone num-
ber i nto the compass uni t memory.
(7) Confi rm that the correct di recti ons are now
i ndi cated by the compass.
COMPASS CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
The el ectroni c compass uni t features a sel f-cal i -
brati ng desi gn, whi ch si mpl i fi es the cal i brati on pro-
cedure. Thi s feature automati cal l y updates the
compass cal i brati on whi l e the vehi cl e i s bei ng dri ven.
Thi s al l ows the compass uni t to compensate for smal l
changes i n the resi dual magneti sm that the vehi cl e
may acqui re duri ng normal use. Do not attempt to
cal i brate the compass near l arge metal objects such
as other vehi cl es, l arge bui l di ngs, or bri dges.
NOTE: Whenever the compass is calibrated manu-
ally, the variation number must also be reset. See
the Compass Variation Adjustment procedure, in
this group.
Cal i brate the compass manual l y as fol l ows:
(1) Start the engi ne. I f the compass/temperature
data i s not currentl y bei ng di spl ayed, momentari l y
depress and rel ease the Step button to step through
the di spl ay opti ons unti l you have reached the com-
pass/temperature di spl ay.
(2) Depress both the U.S./Metri c, and the Step but-
tons. Hol d the buttons down unti l CAL appears i n
the di spl ay. Thi s takes about ten seconds, and
appears about fi ve seconds after VAR i s di spl ayed.
(3) Rel ease both of the buttons.
(4) Dri ve the vehi cl e on a l evel surface, away from
l arge metal objects, through three or more compl ete
ci rcl es i n not l ess than 48 seconds. The CAL mes-
sage wi l l di sappear from the di spl ay to i ndi cate that
the compass i s now cal i brated.
NOTE: If the CAL message remains in the dis-
play, either there is excessive magnetism near the
compass, or the unit is faulty. Repeat the demagne-
tizing and calibration procedures at least one more
time.
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
COMPASS DEMAGNETIZING
A degaussi ng tool (Speci al Tool 6029) i s used to
demagneti ze, or degauss, the overhead consol e for-
ward mounti ng screw and the roof panel . Equi val ent
uni ts must be rated as conti nuous duty for 110/115
vol ts and 60 Hz. They must al so have a fi el d
strength of over 350 gauss at 7 mi l l i meters (0.25
i nch) beyond the ti p of the probe.
To demagneti ze the roof panel and the overhead
consol e forward mounti ng screw, proceed as fol l ows:
(1) Be certai n the i gni ti on swi tch i s i n the Off posi -
ti on, before you begi n the demagneti zi ng procedure.
(2) Pl ug i n the degaussi ng tool , whi l e keepi ng the
tool at l east 61 centi meters (2 feet) away from the
compass uni t.
(3) Sl owl y approach the head of the overhead con-
sol e forward mounti ng screw wi th the degaussi ng
tool pl ugged i n.
(4) Contact the head of the screw wi th the pl asti c
coated ti p of the degaussi ng tool for about two sec-
onds.
(5) Wi th the degaussi ng tool sti l l energi zed, sl owl y
back i t away from the screw. When the ti p of the tool
i s at l east 61 centi meters (2 feet) from the screw
head, unpl ug the tool .
Fig. 1 Variance Settings
(6) Pl ace a pi ece of paper approxi matel y 22 by 28
centi meters (8.5 by 11 i nches), ori ented on the vehi cl e
l engthwi se from front to rear, on the center l i ne of
the roof at the wi ndshi el d header (Fi g. 2). The pur-
pose of the paper i s to protect the roof panel from
scratches, and to defi ne the area to be demagneti zed.
(7) Pl ug i n the degaussi ng tool , whi l e keepi ng the
tool at l east 61 centi meters (2 feet) away from the
compass uni t.
(8) Sl owl y approach the center l i ne of the roof
panel at the wi ndshi el d header, wi th the degaussi ng
tool pl ugged i n.
(9) Contact the roof panel wi th the pl asti c coated
ti p of the degaussi ng tool . Be sure the templ ate i s i n
pl ace to avoi d scratchi ng the roof panel . Usi ng a
sl ow, back-and-forth sweepi ng moti on, and al l owi ng
13 mi l l i meters (0.50 i nch) between passes, move the
tool at l east 11 centi meters (4 i nches) to each si de of
the roof center l i ne, and 28 centi meters (11 i nches)
back from the wi ndshi el d header.
(10) Wi th the degaussi ng tool sti l l energi zed,
sl owl y back i t away from the roof panel . When the
ti p of the tool i s at l east 61 centi meters (2 feet) from
the roof panel , unpl ug the tool .
(11) Cal i brate the compass and adjust the compass
vari ance as descri bed i n thi s group.
OVERHEAD CONSOLE
LONG-TYPE
cabl e.
(2) Remove the forward mounti ng screw, l ocated i n
front of the di spl ay modul e (Fi g. 3).
(3) Sl i de the consol e forward unti l the rear of the
consol e separates from the rear mounti ng bracket.
tri p computer, compass, and thermometer di spl ay
modul e.
(5) Remove the overhead consol e from the vehi cl e.
SHORT-TYPE
cabl e.
(2) Remove the forward mounti ng screw, l ocated i n
front of the di spl ay modul e (Fi g. 4).
bl aded tool , pry gentl y downwards at the rear edge of
the overhead consol e housi ng to rel ease the two snap
cl i p retai ners.
tri p computer, compass, and thermometer di spl ay
modul e and the power sunroof swi tch.
Fig. 2 Roof Demagnetizing Pattern
RH PULL TIP OF DEGAUSSING TOOL AWAY AT LEAST TWO FEET AND DISCONNECT START WINDSHIELD EDGE 1/2 L H
Fig. 3 Overhead Console Remove/Install -Long-Type
OVERHEAD CONSOLE OVERHEAD CONSOLE BRACKET HEADLINER
THERMOMETER DISPLAY MODULE
thi s group.
(2) Remove the screws that secure the tri p com-
puter, compass, and thermometer di spl ay modul e to
the overhead consol e housi ng (Fi g. 5).
(3) Unpl ug the l i ghti ng and push button wi re har-
ness connectors from the tri p computer, compass, and
thermometer di spl ay modul e.
(4) Remove the modul e from the overhead consol e
housi ng.
PUSH BUTTON MODULE
thi s group.
push button modul e.
(3) Remove the four screws (l ong-type consol e) or
two screws (short-type consol e) that secure the push
button modul e to the consol e housi ng.
(4) Remove the push button modul e from the con-
sol e.
READING AND COURTESY LAMP BULB
(1) I nsert a l ong, narrow, fl at-bl aded tool at the
notch on the curved edge of the readi ng and courtesy
l amp l ens.
(2) Gentl y pry the l ens downward from the over-
head consol e housi ng and pi vot the l ens down. I t may
be necessary to move the tool al ong the edge of the
l ens to free the l ens from the consol e housi ng.
(3) Remove the bul b by pul l i ng i t strai ght down
from the l amp socket.
(4) I nstal l a new bul b by al i gni ng i ts base wi th the
socket, and pushi ng the bul b fi rml y i nto pl ace.
(5) Pi vot the l ens back up i nto posi ti on and press
upward fi rml y unti l i t snaps i nto pl ace.
(6) Test the l amp by depressi ng the l ens to check
for proper l amp swi tchi ng and l i ghti ng.
Fig. 4 Overhead Console Remove/Install -Short-Type
BRACKET SNAP CLIPS SCREW MINI OVERHEAD CONSOLE SCREW
Fig. 5 Trip Computer, Compass, and
ThermometerDisplay Module Remove/Install -
Typical
AMBIENT TEMPERATURE SENSOR
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. 6).
(4) Unpl ug the temperature sensor wi re harness
connector.
(5) Remove the temperature sensor mounti ng bol t
and remove the sensor.
Fig. 6 Temperature Sensor Remove/Install
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-36-1
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
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
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
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
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
Fig. 5 Symbol Identification
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.
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
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
the si de of the ci rcui t cl osest to the battery (Fi g. 10).
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
(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.
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
(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
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 REPLACEMENT
(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
(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.
CONNECTOR AND TERMINAL REPLACEMENT
(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.
si de of the wi re. Be sure the tubi ng wi l l be l ong
part of the exposed wi res.
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
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
(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
(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
(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.
(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.
(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. 24 Diode Identification
(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.
(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 Remov3ing Tool 6932
Terminal Removing Tool 6934
8W-02 COMPONENT INDEX
INDEX
page
GENERNAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Crankshaft Posi ti on (CKP) Sensor . . . . . . . . . 8W-30
Crui se Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Component Page
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
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-30
ZG 8W - 02 COMPONENT INDEX 8W - 02 - 1
Component Page
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
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
Component Page
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
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
Component Page
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
Transmi ssi on Control Rel ay . . . . . . . . . . . 8W-30, 31
Transmi ssi on Sol enoi d Assembl y . . . . . . . 8W-30, 31
Component Page
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
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
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 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-10-17 FOR PDC PIN-OUT INFORMATION
8W - 10 - 2 8W-10 POWER DISTRIBUTION ZG
J978W-3 ZG001001
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)
(8W-10-4)
(8W-10-4)
(8W-10-5)
(8W-10-6)
(8W-10-7)
(8W-10-9)
(8W-10-10)
(8W-10-12)
(8W-10-14)
(8W-10-13)
(8W-10-14)
(8W-10-13)
(8W-20-2)
(8W-20-3)
(8W-10-11)
(8W-10-18)
(8W-10-12)
(8W-10-14)
ZG 8W-10 POWER DISTRIBUTION 8W - 10 - 3
ZG001002 J978W-3
(GAS)
(8W-10-16)
A15
A16
18
(8W-30-27)
15A
FUSE
FUSE
A20
A19
S101
TO
BR
F99
18
25A
(8W-10-18)
(DIESEL)
20
TO
AUTO
SHUT
RELAY
DOWN
RD/YL
14
F5
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
CENTER
DISTRIBUTION
POWER
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
CENTER
DISTRIBUTION
POWER
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
(8W-10-3)
(8W-10-3)
(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)
J978W-3 ZG001003
85
5
FUSE
50A
4
11
CENTER
DISTRIBUTION
POWER
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
(8W-39-6)
(8W-41-2)
(8W-10-3)
(8W-10-3)
(8W-39-6)
(8W-41-2)
(8W-39-6)
(8W-41-2)
(8W-35-2)
ZG001004 J978W-3
7
FUSE
40A
6
13
CENTER
DISTRIBUTION
POWER
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 (8W-42-2)
(8W-42-3)
(8W-10-3)
(8W-10-3)
(8W-42-3)
(8W-42-3)
(8W-42-3)
J978W-3 ZG001005
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)
ZG001006 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
CENTER
DISTRIBUTION
POWER
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
(8W-10-13)
(8W-10-14)
(8W-10-3)
(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)
J978W-3 ZG001007
23
16
10
FUSE
20A
CENTER
DISTRIBUTION
POWER
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
(8W-10-3)
(8W-10-7) (8W-10-3)
(8W-12-4)
(8W-12-4) (8W-12-3) (8W-12-3)
(8W-12-3)
(8W-12-2)
ZG001008 J978W-3
FUSE
10A
15
(8W-12-20)
87
REAR
FOG
LAMP
RELAY
(8W-51-7)
30
17
24
11
FUSE
50A
CENTER
DISTRIBUTION
POWER
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(+)
(8W-10-3)
(8W-10-3)
(8W-35-2)
(8W-12-8) (8W-12-8) (8W-12-7)
(8W-12-7)
(8W-12-2)
J978W-3 ZG001009
26
13
FUSE
30A
19
CENTER
DISTRIBUTION
POWER
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
(8W-10-3)
(8W-10-3)
(8W-50-2)
(8W-12-2)
(8W-50-5)
(8W-50-2)
(8W-12-14)
(8W-50-2)
ZG001010 J978W-3
28
21
15
FUSE
40A
CENTER
DISTRIBUTION
POWER
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
(8W-10-3)
(8W-10-3)
(8W-12-18)
(8W-12-16)
(8W-12-16)
(8W-12-16)
(8W-12-12)
(8W-12-11)
(8W-12-2)
J978W-3 ZG001011
A11
A12
16
FUSE
15A
CENTER
DISTRIBUTION
POWER
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 (+)
(8W-12-24)
(8W-50-7)
(8W-50-6) (8W-50-6)
(8W-50-6)
(8W-12-2)
(8W-10-3)
(8W-10-8) (8W-10-3)
(8W-30-22)
ZG 8W-10 POWER DISTRIBUTION
DIESEL ENGINE
8W - 10 - 13
ZG001012 J978W-3
A11
A12
16
FUSE
20A
CENTER
DISTRIBUTION
POWER
BATT A0
A61
16
DG/BK
C16
C17
(IN PDC)
RELAY
PUMP
FUEL
A64
16
DG/WT
18 C304
A64
16
DG/WT
1
FUEL
PUMP
MODULE
17
FUSE
15A
A13
A14
F92
18
LG
A6
A7
(IN PDC)
RELAY
TRANSMISSION
T20
18
LB
1 C131
T20
18
LB
1
TRANSMISSION
SOLENOID
ASSEMBLY
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
CONTROL
(8W-12-24)
(8W-50-7)
(8W-50-6) (8W-50-6)
(8W-50-6)
(8W-12-2)
(8W-10-3)
(8W-31-2)
(8W-10-8) (8W-10-3)
(8W-31-2)
(8W-31-3)
(8W-30-16)
(8W-30-16)
8W - 10 - 14 8W-10 POWER DISTRIBUTION
GAS ENGINES
ZG
J978W-3 ZG001016
F99
18
OR
C1 A2
F99
18
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
18
OR
F99
(8W-30-27)
(8W-30-22)
(8W-45-2)
(8W-30-4)
(8W-30-4)
(8W-30-4)
(8W-30-5)
(8W-30-16)
(8W-42-10)
(8W-30-4)
(8W-30-22)
(8W-10-14)
ZG001013 J978W-3
A19
20
FUSE
20A
A20
CENTER
DISTRIBUTION
POWER
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)
(8W-10-3)
(8W-10-3)
(8W-30-5)
(8W-30-4)
(8W-30-5)
GAS ENGINES
ZG
J978W-3 ZG001014
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)
GAS ENGINES
8W - 10 - 17
ZG001015 J978W-3
25A
FUSE
20
30A
FUSE
4
A12
12
RD/TN
BATT F61
D10
B18 B16
B17
CENTER
DISTRIBUTION
POWER
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
(8W-10-9)
(8W-10-3)
(8W-30-27)
(8W-30-27)
DIESEL ENGINE
ZG
J978W-3 ZG001017
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)
DIESEL ENGINE
8W - 10 - 19
ZG001018 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
J978W-3 ZG001019
**
FUSED B(+) F6 18WT/RD
15 16 *
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
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
ZG001020 J978W-3
AUTOMATIC
SHUT DOWN
RELAY
B18
A142 16DG/OR
B17
B16
F5 18RD/YL FUSED B(+)
FUSED B(+)
FUSED B(+)
WIPER PARK SWITCH SENSE V6 16DB
C1
F86 16LG/RD*
F86 16LG/RD**
C2
C3
F86 16LG/RD
RELAY
WIPER
INTERMITTENT
K900 20PK/WT B20 AUTOMATIC SHUT DOWN RELAY CONTROL
C5
C4
V66 18VT/WT
V18 20YL/LG
WIPER PARK SWITCH SENSE
INTERMITTENT WIPER RELAY CONTROL
FUSED B(+)
FUSED B(+)
J978W-3 ZG001021
*DIESEL
**GAS
B16
FUSED B(+)*
B16
B17
B17
F5 16 RD/YL FUSED B(+)
FUSED B(+)*
F5 16RD/YL*
F5 16RD/YL*
A142 16DG/OR* FUSED B(+)*
A142 18DG/OR FUSED B(+)
- -
C9
C8
T141 14YL/TD FUSED IGNITION SWITCH OUTPUT (ST)
T40 12LG/BK
C7
C6
A1 12RD/WT FUSED B(+)
ENGINE STARTER MOTOR RELAY OUTPUT
FUEL PUMP RELAY OUTPUT
FUSED B(+) A61 16DG/BK
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
-
ENGINE
STARTER
MOTOR
RELAY
ZG001022 J978W-3
C10
T41 20BK/WT
*
**
FUEL HEATER FEED
GROUND
D14
(DIESEL)
RELAY
HEATER
FUEL
D12
D13
D11
CAV
D10
A64 14OR/DB
A12 12RD/TN
CIRCUIT
Z4 20BK
FUSED B(+)
FUNCTION
- -
F99 20OR FUSED IGNITION SWITCH OUTPUT (START/RUN)
*GAS
**DIESEL
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
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
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 22
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
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-12-14, 20, 24
Component Page
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
Juncti on Bl ock . . . . . . 8W-12-2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 14,
15, 16, 17, 18, 19, 22, 23, 24
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 ndow Defogger Rel ay . . . . . . . . . . . . . . . . . 8W-12-9
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . . . . . . . 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
J978W-3 ZG001201
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-47-2)
(8W-41-3)
(8W-10-9) (8W-10-9)
(8W-41-3)
ZG 8W-12 JUNCTION BLOCK 8W - 12 - 3
ZG001202 J978W-3
C10
5
10A
FUSE
3
JUNCTION
BLOCK
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
(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)
J978W-3 ZG001203
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
JUNCTION
BLOCK
1
C2
A16
18
FUSE
15A
A15
CENTER
DISTRIBUTION
POWER
A21
12
DB/GY
17
AIRBAG
CONTROL
MODULE
10A
FUSE
5
7
C13 C9
3
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
(8W-40-5)
(8W-12-2)
(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)
ZG001204 J978W-3
C8
1
15A
FUSE
6
RUN A22
JUNCTION
BLOCK
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
(8W-50-11)
(8W-51-5)
(8W-12-2)
(8W-10-8)
(8W-52-2)
(8W-52-6)
(8W-46-4) (8W-46-2)
(8W-65-2) (8W-30-10)
J978W-3 ZG001205
G18
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
JUNCTION
BLOCK
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
(8W-12-2)
(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)
ZG001206 J978W-3
20A
FUSE
8
C14
8
BATT A250
JUNCTION
BLOCK
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
8
C4
F75
18
VT
C2 8
MODULE
CONTROL
BODY
F70
16
PK/BK
6 C372
7
(8W-12-2)
(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)
J978W-3 ZG001207
C6
3
BATT A900
85 87
30 86
REAR
WINDOW
DEFOGGER
RELAY
JUNCTION
BLOCK
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
(8W-48-2)
(8W-12-2)
(8W-45-3)
(8W-10-4) (8W-10-8)
(8W-35-2)
(8W-48-2)
(8W-48-2) (8W-48-2)
ZG001208 J978W-3
10A
FUSE
12
C9
9
JUNCTION
BLOCK
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
(8W-12-2)
(8W-42-7)
(8W-10-8)
(8W-42-9)
(8W-42-5)
(8W-63-14) (8W-63-13)
(8W-44-11)
(8W-42-9)
J978W-3 ZG001209
C5
4
JUNCTION
BLOCK
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
(8W-46-6)
(8W-47-3)
(8W-47-3)
(8W-47-4)
(8W-47-3)
(8W-10-12)
(8W-52-2)
(8W-15-17)
(8W-15-17)
(8W-15-18)
(8W-15-18)
(8W-47-3)
(8W-12-2)
(8W-52-2)
ZG001210 J978W-3
10A
FUSE
16
C8
8
JUNCTION
BLOCK
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)
(8W-12-2)
(8W-10-12)
(8W-44-5)
(8W-44-2)
(8W-44-2)
(8W-44-2)
(8W-44-2)
(8W-44-2)
(8W-44-8)
J978W-3 ZG001211
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)
ZG001212 J978W-3
15A
FUSE
17
C10
10
JUNCTION
BLOCK
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
(8W-12-2)
(8W-45-4)
(8W-10-11)
(8W-50-7)
J978W-3 ZG001213
C13
4
L90
18
DB/RD
(OPTIONAL)
MODULE
OUTAGE
LAMP
3 4 5
L90 18DB/RD L90 18DB/RD
FROM
JUNCTION
BLOCK
OUTPUT
JUNCTION
BLOCK
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
(8W-12-2)
(8W-50-9) (8W-50-10)
(8W-47-2)
(8W-46-6)
(8W-51-2)
ZG001214 J978W-3
15A
FUSE
19
C7
2
BATT A7
JUNCTION
BLOCK
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
(8W-12-2)
(8W-10-12)
(8W-41-3)
(8W-46-4) (8W-46-2)
(8W-47-2)
(8W-42-2)
(8W-50-2)
J978W-3 ZG001215
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
JUNCTION
BLOCK
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
TURN
SIGNAL
SWITCH
RIGHT RIGHT
REPEATER
SIDE
(8W-52-8)
(8W-12-2)
(8W-44-6)
(8W-52-2)
(8W-52-8)
(8W-51-6)
(8W-51-6)
(8W-54-4)
(8W-44-6)
(8W-40-4)
ZG001216 J978W-3
B
L64
TN/DB
18
(8W-52-3)
RIGHT
SIGNAL
FRONT
LAMP
TN/DB
A
18
L64
TURN
S413
TN/DB
L64
18
MARKER
LAMP
(8W-52-3)
SIDE
FRONT
RIGHT
1 C150
1 C150
OTHERS
REPEATER
LAMPS
SIDE
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-12-2)
(8W-10-12)
(8W-63-3)
(8W-63-8)
(8W-63-14)
(8W-63-2)
(8W-63-4)
(8W-63-13)
(8W-63-9)
J978W-3 ZG001217
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
JUNCTION
BLOCK
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
(8W-46-3) (8W-46-5)
(8W-12-2)
(8W-46-3)
(8W-46-5)
(8W-46-3) (8W-46-5)
ZG001218 J978W-3
BATT F61
10A
FUSE
15
86 30
87
BLOCK
JUNCTION
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
C307
(8W-10-9)
(8W-12-2)
(8W-51-7)
(8W-51-7)
J978W-3 ZG001219
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)
ZG001220 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
JUNCTION
BLOCK
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
(8W-12-2)
(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)
J978W-3 ZG001221
A5
(IN PDC)
C7
12
C3 1
JUNCTION
BLOCK
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
(8W-12-2)
(8W-43-2)
(8W-10-8)
(8W-45-3)
(8W-41-2)
(8W-41-2)
ZG001222 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
JUNCTION
BLOCK
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
(8W-45-5)
(8W-12-2)
(8W-10-11) (8W-10-13)
(8W-10-14)
(8W-50-7)
(8W-50-6) (8W-50-6)
(8W-45-5)
(8W-50-2)
(8W-50-2)
J978W-3 ZG001223
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
FEED 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
ZG001224 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
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
J978W-3 ZG001225
A31 12RD/BK
20A 1**
F86 18LG/BK
*GAS
**DIESEL
C15 BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
87
86
A900 OR/YL FUSED B(+)
C14 WT/RD
85
30
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 18VT/TN
L5 18OR/BK
Z1 18BK
CAVITY
1
2
3
4
5
TURN SIGNAL
HAZARD SIGNAL
GROUND
CIRCUIT FUNCTION
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (RUN)
ELECTRONIC
FLASHER
(I)
ZG001226 J978W-3
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
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
J978W-3 ZG001227
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.
8W-15 GROUND DISTRIBUTION
INDEX
page
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
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 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 No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7
Horn No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 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 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 Left Turn Rel ay . . . . . . . . . . . . . . . . . . . . 8W-15-9
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . . . . . . . . . 8W-15-9
Trai l er Tow Stop Lamp Rel ay . . . . . . . . . . . . . . . . . . . 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
J978W-3 ZG001501
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 8W-15 GROUND DISTRIBUTION
DIESEL ENGINE
8W - 15 - 3
ZG001515 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)
DIESEL ENGINE
ZG
J978W-3 ZG001502
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)
GAS ENGINES
8W - 15 - 5
ZG001516 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)
DIESEL ENGINE
ZG
J978W-3 ZG001503
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)
GAS ENGINES
8W - 15 - 7
ZG001517 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
10
Z4
(DIESEL)
(IN PDC)
RELAY
MOTOR
C10
STARTER
ENGINE
(8W-21-3)
(8W-21-4)
(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
J978W-3 ZG001504
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 8W-15 GROUND DISTRIBUTION 8W - 15 - 9
ZG001505 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
MOTOR
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)
J978W-3 ZG001506
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)
ZG001507 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
LAMP
COURTESY
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
(8W-44-2) (8W-60-2)
(8W-61-2)
(8W-62-2)
(8W-60-2)
(8W-61-2)
(8W-62-2)
(8W-46-6) (8W-51-5)
J978W-3 ZG001508
RADIO
Z5
16
BK/LB
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)
ZG001509 J978W-3
2
LAMP
COURTESY
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
(8W-60-4)
(8W-44-2) (8W-60-3)
(8W-61-3)
(8W-62-3)
(8W-60-3)
(8W-61-3)
(8W-62-3)
J978W-3 ZG001510
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)
ZG001511 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)
J978W-3 ZG001512
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)
ZG001513 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)
J978W-3 ZG001514
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.
8W-20 CHARGING SYSTEM
INDEX
page
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 - 20 - 2 8W-20 CHARGING SYSTEM
DIESEL ENGINE
ZG
J978W-3 ZG002001
1
(8W-30-23)
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
18
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 8W-20 CHARGING SYSTEM
GAS ENGINES
8W - 20 - 3
ZG002003 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)
DIESEL ENGINE
ZG
J978W-3 ZG002002
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 8W-20 CHARGING SYSTEM
GAS ENGINES
8W - 20 - 5
ZG002004 J978W-3
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)
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.
erator fi el d on ci rcui t K20.
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
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . 8W-21-3
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
A41B
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
J978W-3 ZG002102
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
A41B
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 8W-21 STARTING SYSTEM
DIESEL ENGINE
8W - 21 - 3
ZG002101 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
PN
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-44-6)
(8W-30-10)
(8W-10-7)
(8W-10-7)
GAS ENGINES
ZG
J978W-3 ZG002103
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
8W-30 FUEL/IGNITION SYSTEMS
INDEX
page
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
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 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 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
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 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 5
G103 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-30
G103 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
G104 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-22
Component Page
G104 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
G105 4.0L Engi ne . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-14
G105 5.2L Engi ne . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13
G106 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . 8W-30-26, 28
G107 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-27
G123 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-24
G304 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10
G305 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28
G305 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16
Generator Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
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
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
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
20
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
J978W-3 ZG003001
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
18
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 8W-30 FUEL/IGNITION SYSTEM
GAS ENGINES
8W - 30 - 3
ZG003002 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
18
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)
GAS ENGINES
ZG
J978W-3 ZG003003
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)
GAS ENGINES
8W - 30 - 5
ZG003004 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-70-3)
(8W-70-2)
GAS ENGINES
ZG
J978W-3 ZG003005
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
(8W-70-3)
(8W-70-3)
(8W-70-4)
(8W-30-8)
(8W-30-9)
(8W-30-8)
(8W-30-9)
GAS ENGINES
8W - 30 - 7
ZG003006 J978W-3
*3
**5.2 V-8
*4.0L 1-6
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)
5.2L ENGINE
ZG
J978W-3 ZG003007
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)
4.0L ENGINE
8W - 30 - 9
ZG003008 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)
GAS ENGINES
ZG
J978W-3 ZG003009
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)
5.2L ENGINE
8W - 30 - 11
ZG003010 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)
5.2L ENGINE
ZG
J978W-3 ZG003011
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)
5.2L ENGINE
8W - 30 - 13
ZG003012 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)
4.0L ENGINE
ZG
J978W-3 ZG003013
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)
4.0L ENGINE
8W - 30 - 15
ZG003014 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)
GAS ENGINES
ZG
J978W-3 ZG003015
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)
GAS ENGINES
8W - 30 - 17
ZG003016 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-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)
GAS ENGINES
ZG
J978W-3 ZG003017
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)
GAS ENGINES
8W - 30 - 19
ZG003018 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
5.2L ENGINE
ZG
J978W-3 ZG003019
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
4.0L ENGINE
8W - 30 - 21
ZG003020 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
(8W-12-20)
(8W-10-8)
(8W-10-3)
(8W-10-13)
(8W-10-15)
(8W-10-15)
(8W-10-3)
DIESEL ENGINE
ZG
J978W-3 ZG003021
A/C
SIGNAL
37
SWITCH
CONTROL
COMPRESSOR
CLUTCH
RELAY
A/C
28
1
59
DG
20
C103
DB/RD
C13
16
DB/RD
16
C13
C132
POWERTRAIN
CONTROL
MODULE
A/C
LOW
PRESSURE
SWITCH
(8W-42-13)
SIGNAL
SWITCH
A/C
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
DIESEL ENGINE
8W - 30 - 23
ZG003022 J978W-3
DRIVER
FIELD
GENERATOR
C4 20
3
K20
18
DG/YL
(8W-20-2)
GENERATOR
12 8
CONTROLLER
MSA
43
NEEDLE
MOVEMENT
SENSOR
(+) SIGNAL
SENSOR
SPEED
VEHICLE CRANK
POSITION
SENSOR
SIGNAL
11 21
(+)
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
(8W-33-5)
(8W-70-9)
DIESEL ENGINE
ZG
J978W-3 ZG003023
(DIESEL)
BK/LB
K4
20
(8W-70-8)
S136
2
TACH
SIGNAL
24 C4
GY/LB
G21
20
TACH
SIGNAL
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
(8W-70-7)
DIESEL ENGINE
8W - 30 - 25
ZG003024 J978W-3
33
SENSOR
GROUND
GROUND
4
BK/LB
K4
20
BK/LB
20
K4
(8W-70-8)
S136
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)
DIESEL ENGINE
ZG
J978W-3 ZG003025
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-12-5)
(8W-39-2)
(8W-10-15)
(8W-70-7)
(8W-15-8)
(8W-15-8)
DIESEL ENGINE
8W - 30 - 27
ZG003026 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)
DIESEL ENGINE
ZG
J978W-3 ZG003027
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
(8W-70-9)
(8W-70-9)
(8W-70-8)
DIESEL ENGINE
8W - 30 - 29
ZG003028 J978W-3
5
20
ON/OFF
SWITCH
CONTROL
SPEED
SENSE
STOP
SENSE
SWITCH
LAMP
44
3
V32
20
YL/RD
L50
18
WT/TN
V32
YL/RD
20
V32
YL/RD
20
8
WT/TN
18
L50
WT/TN
18
L50
9 C132
F9
(8W-70-5)
S337
(8W-70-5)
S312
9
C305
12
1
24 C4
SENSE
SWITCH
STOP
LAMP
BR
L53
20
BR
L53
20
BR
20
L53
C234
C132
STOP
LAMP
SWITCH
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)
DIESEL ENGINE
ZG
J978W-3 ZG003029
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)
DIESEL ENGINE
8W - 30 - 31
ZG003030 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)
DIESEL ENGINE
ZG
J978W-3 ZG003031
INDEX
page page
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
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
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
VEHICLE SPEED SENSOR (DIESEL) . . . . . . . . 35
WATER IN FUEL SENSOR (DIESEL) . . . . . . . . . 38
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.
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
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.
i nsi de the rel ay cl ose and connect ci rcui t F5 from
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
Refer to the appropri ate secti on of the servi ce
manual or Di agnosti c Test Procedures manual
FUEL PUMP RELAY
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
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)
FUEL PUMP MOTOR
rel ay powers the fuel pump motor. Ci rcui t Z1 pro-
8W - 30 - 34 8W - 30 FUEL/IGNITION SYSTEMS ZG
FUEL LEVEL SENSOR
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.
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:
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
an i nput si gnal to the PCM.
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
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.
Fuel pump modul e
Vehi cl e speed 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.
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.
Fuel pump modul e
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.
posi ti on sensor (ci rcui t K24) through ci rcui t K4.
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.
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.
Fuel pump modul e
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
Fuel pump modul e
(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.
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.
Ci rcui t K22 del i vers the TPS si gnal to the PCM.
The PCM provi des a ground for the throttl e posi -
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.
Fuel pump modul e
(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
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.
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
HELPFUL INFORMATION
Refer to Group 14 for MAP sensor operati on.
shaft posi ti on sensor, crankshaft posi ti on sensor and
throttl e posi ti on sensor.
Fuel pump modul e
MASS AIR FLOW SENSOR (DIESEL)
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-
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
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
Fuel pump modul e
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 Powertrai n Control Modul e on ci rcui t G60.
sor on ci rcui t K4.
CCD bus. The mi cro-processor i n the i nstrument
cl uster recei ves the si gnal from the CCD bus, cal cu-
l ates oi l pressure and adjusts the gauge needl e posi -
ti on.
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
FUEL INJECTORS
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.
Ci rcui t K12 provi des ground for i njector number two.
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.
Ci rcui t K38 provi des ground for i njector number fi ve.
Ci rcui t K58 provi des ground for i njector number si x.
On the 5.2L engi ne, ci rcui t K17 provi des ground
for i njector number seven. The K17 ci rcui t connects
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 Con-
trol Modul e (PCM) and the fuel temperature sensor. The
sensor i s a vari abl e resi stor. As fuel temperature
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 .
FUEL QUANTITY ACTUATOR
Power for the fuel quanti ty Actuator i s suppl i ed on
are CLOSED. Ground for the Actuator i s control l ed
FUEL HEATER (DIESEL)
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
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
HELPFUL INFORMATION
i njectors, PCM, heated oxygen sensors, and generator.
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
DUTY CYCLE EVAP\PURGE SOLENOID
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 e-
sel Powertrai n Control Modul e (PCM) rel ay are
CLOSED. Ground for the sol enoi d i s suppl i ed on ci rcui 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
8W-31 TRANSMISSION CONTROL SYSTEM
INDEX
page
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
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
18
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
J978W-3 ZG003101
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 8W-31 TRANSMISSION SYSTEM 8W - 31 - 3
ZG003102 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
J978W-3 ZG003103
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-10-5)
(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 8W-31 TRANSMISSION SYSTEM 8W - 31 - 5
ZG003104 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
1 4 3
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
2
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
(8W-70-2)
(8W-30-23)
8W - 31 - 6 8W-31 TRANSMISSION SYSTEM
DIESEL ENGINE
ZG
J978W-3 ZG003105
INDEX
page page
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
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.
posi ti ons, i t connects ci rcui t A1 from fuse 8 i n the
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
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
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
Fuel pump modul e
8W - 31 - 8 8W - 31 TRANSMISSION CONTROL SYSTEM ZG
8W-33 VEHICLE SPEED CONTROL
INDEX
page
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
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-30-4)
(8W-30-10)
8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL
GAS ENGINES
ZG
J978W-3 ZG003301
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 8W-33 VEHICLE SPEED CONTROL
GAS ENGINES
8W - 33 - 3
ZG003302 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)
DIESEL ENGINE
ZG
J978W-3 ZG003303
(8W-30-29)
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 8W-33 VEHICLE SPEED CONTROL
DIESEL ENGINE
8W - 33 - 5
ZG003304 J978W-3
VEHICLE SPEED CONTROL
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
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)
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.
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.
l evel on ci rcui t K95 at the PCM has nomi nal val ue of
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.
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.
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
PCM.
8W - 33 - 6 8W - 33 VEHICLE SPEED CONTROL ZG
8W-35 ALL-WHEEL ANTI-LOCK BRAKES
INDEX
page
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
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
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
16
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
J978W-3 ZG003501
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 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3
ZG003502 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
J978W-3 ZG003503
INDEX
page page
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . 5
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . 5
G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 5
STOP LAMP SWITCH INPUT . . . . . . . . . . . . . . . 5
WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . 5
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.
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.
from the l eft front wheel speed sensor.
from ri ght rear wheel speed sensor.
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
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.
8W-39 VEHICLE THEFT SECURITY SYSTEM
INDEX
page
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
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
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
8
FUSE
40A
BATT A0
POWER
DISTRIBUTION
CENTER
7
14 A16
A15
15A
FUSE
18
A1
12
RD/WT RD/WT
12
A1
E1 C233
RD/WT
12
A1
IGNITION
SWITCH
1 START
2 RUN
0 OFF
3 ACC
3
0 2
1
4
2 6
7
1
2 0
3
C6
(IN PDC)
RELAY
MOTOR
STARTER
ENGINE
BODY
CONTROL
MODULE
A1
12
RD/WT
A1
12
RD/WT
10A
FUSE
3
BLOCK
JUNCTION
A31
12
RD/BK
1 C6
DB/GY
12
A21
C6 2
C2 15
BR/PK
20
V23
5
C10
FUSED
IGN.
(RUN-ACC)
1 C2
A21
12
DB/GY
(ST-RUN)
IGN.
FUSED
18 C1
F99
18
OR
F99
20
OR
H8 C236
F99
20
OR
S101
S210
(8W-10-15)
(8W-12-2)
(8W-12-4)
(8W-45-2)
(8W-21-3)
(8W-21-4)
(8W-10-7)
(8W-10-13)
(8W-10-14)
(8W-10-3)
(8W-10-3)
(8W-10-7)
8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM ZG
J978W-3 ZG003901
13
FUSE
30A
BATT A0
POWER
DISTRIBUTION
CENTER
26
19 17
24
50A
FUSE
11
A6
14
RD/LB
BODY
CONTROL
MODULE
RD
10
A250
8 C1 C2 4
7
FUSE
20A 15A
FUSE
17
BLOCK
JUNCTION
87 85
30 86
PARK
LAMP
RELAY
2
1
LED
VTSS
SENSOR/
LIGHT
HEADLAMP
AUTOMATIC
G69
20
BK/LG
C1 23
VTSS
INDICATOR
LAMP
DRIVER
F75
18
VT
F75
18
VT
8
C4 C4
9 11
C10
10
C10
S201
CONTROL
RELAY
LAMP
PARK
C2 21 17 C1
PARK
LAMP
RELAY
OUTPUT
B (+)
FUSED
C2 8
L79
20
TN
L90
20
DB/RD
F75
18
VT
(8W-12-8)
(8W-45-4)
(8W-50-5)
(8W-12-2)
(8W-12-14) (8W-12-8)
(8W-45-4)
(8W-10-10)
(8W-10-3)
(8W-10-3)
(8W-10-11)
ZG 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3
ZG003902 J978W-3
24
C2
Z1
16
BK
S202
Z1
14
BK
2 C301
Z1
14
BK BK/OR
18
Z2
C307 8
BK/OR
18
Z2
S205
BK/OR
20
Z2
C1
16 8
C3
Z2
18
BK/OR
S302
BODY
CONTROL
MODULE
C1
12
HOOD
AJAR
SWITCH
SENSE
(VTSS)
G70
20
BR/TN
G6
C235
G4
BR/TN
20
G70
HOOD
SWITCH
SENSE
SWITCH
AJAR
LIFTGATE
TN/BK
20
G78
1
C3
9
C321
G78
20
TN/BK
G78
20
TN/BK
2
1
SWITCH
AJAR
LIFTGLASS
BK
20
Z1 Z1
20
BK
LIFTGATE
AJAR
SWITCH
1
2
TN/BK
20
G78
S329
S328
G300
Z1
12
BK
2
C325
Z1
12
BK
Z1
12
BK
S316
G304
Z2
18
BK/OR
6
3
(8W-15-18) (8W-15-18)
(8W-15-18)
(8W-45-2)
(8W-45-10)
(8W-44-14)
(8W-45-11)
(8W-15-10)
(8W-15-11)
(8W-15-11)
(8W-15-18)
J978W-3 ZG003903
BODY
CONTROL
MODULE
LEFT
REAR
DOOR
AJAR
SWITCH
13
C3
G77
18
TN/OR
LEFT
REAR
DOOR
AJAR
SWITCH
SENSE SENSE
SWITCH
AJAR
DOOR
FRONT
LEFT
TN
18
G75
C3
4
SWITCH
AJAR
DOOR
FRONT
LEFT RIGHT
FRONT
DOOR
AJAR
SWITCH
9
C3
G74
18
TN/RD
RIGHT
FRONT
DOOR
AJAR
SWITCH
SENSE SENSE
SWITCH
AJAR
DOOR
REAR
RIGHT
TN/YL
18
G76
C3
3
SWITCH
AJAR
DOOR
REAR
RIGHT
10
C3
G71
20
VT/YL
VTSS
DISARM
SENSE
G71
20
VT/YL
3 C321
VT/YL
20
G71
LIFTGATE
CYLINDER
LOCK
SWITCH
1
2
Z1
20
BK
Z1
12
BK
G300
S328
2
C325
Z1
12
BK
Z1
12
BK
S316
BK
12
Z1
C351 1
S325
G301
BK
12
Z1
BK
20
Z1
2
1
G71
20
VT/YL
C351 14
VT/YL
20
G71
BK
12
Z1
C334 1
S324
G302
BK
12
Z1
BK
20
Z1
2
1
G71
20
VT/YL
C334 14
VT/YL
20
G71
S305
LEFT
FRONT
CYLINDER
LOCK
SWITCH
LOCK
CYLINDER
FRONT
RIGHT
SWITCH
3
(8W-15-11)
(8W-15-10)
(8W-15-11)
(8W-15-14)
(8W-15-14)
(8W-15-12)
(8W-15-12)
ZG 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 5
ZG003904 J978W-3
6
FUSE
20A
BATT A0
POWER
DISTRIBUTION
CENTER
5
12
F31
16
VT
A1
(IN PDC)
RELAY
HORN
A3
A2 A5
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
(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)
J978W-3 ZG003905
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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
operates 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 Mod-
ul e (PDM) recei ves the PANI C si gnal and broadcasts a
message on the CCD bus. When the BCM sees the
PANI C message 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 nutes 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.
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.
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 ft-
gate 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 Sys-
tem i s armed, the BCM starts the al arm. Refer to the
I ntroducti 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 sec-
onds, 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
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 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 r-
cui 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.
8W-40 INSTRUMENT CLUSTER
INDEX
page
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 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
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
J978W-3 ZG004001
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 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3
ZG004002 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)
J978W-3 ZG004003
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
(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 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
ZG004004 J978W-3
BK/WT
20
F87
DIESEL
LAMP
DRIVER
GAS
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-45-9)
(8W-50-4)
J978W-3 ZG004005
INDEX
page page
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
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 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 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
on ci rcui t 205.
HELPFUL INFORMATION
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
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
8W-41 HORN/CIGAR LIGHTER
INDEX
page
Component Page
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 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
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
J978W-3 ZG004101
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 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3
ZG004102 J978W-3
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
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
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
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
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
BLOCK
RESISTOR
MOTOR
BLOWER
C7
12
BK
C7
12
BK/TN
C7
12
BK/TN
B C206
BLOWER
MOTOR
SWITCH
M
C1
(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 - 2 8W-42 AIR CONDITIONING-HEATER ZG
J978W-3 ZG004201
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 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
ZG004202 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
J978W-3 ZG004203
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 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5
ZG004204 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
J978W-3 ZG004205
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 8W-42 AIR CONDITIONING-HEATER
MANUAL
8W - 42 - 7
ZG004206 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)
ATC
ZG
J978W-3 ZG004207
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)
ATC
8W - 42 - 9
ZG004208 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)
GAS DIESEL
F
(8W-42-5)
TO
C131
(8W-10-4)
(8W-10-4)
(8W-10-8)
(8W-10-3)
(8W-10-15)
(8W-10-13)
(8W-42-7)
GAS ENGINES
ZG
J978W-3 ZG004209
21
FUSE
15A
A21
A22
F250
18
RD/GY
CENTER
DISTRIBUTION
POWER
B1 B3
B5 B2
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-10-18)
(8W-10-3)
(8W-10-4)
DIESEL ENGINE
8W - 42 - 11
ZG004211 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)
GAS ENGINES
ZG
J978W-3 ZG004210
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)
(8W-30-29)
DIESEL ENGINE
8W - 42 - 13
ZG004212 J978W-3
SWITCH
SIGNAL
A/C
37
(8W-30-22)
POWERTRAIN
CONTROL
MODULE
DG
C103
20
59 C4
A/C
SIGNAL
SWITCH
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C OPERATIONAUTOMATIC TEMPERATURE
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A/C OPERATIONMANUAL A/C . . . . . . . . . . . . 14
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
BLOWER MOTORMANUAL A/C-HEATER . . . . 14
IN-CAR TEMPERATURE SENSOR . . . . . . . . . . 15
MANUAL A/C-HEATER . . . . . . . . . . . . . . . . . . . 14
MODE DOOR MOTORAUTOMATIC
RECIRCULATION DOOR MOTORAUTOMATIC
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.
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.
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.
passes through one resi stor i n the resi stor bl ock to
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
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
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.
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
connects to the ATC modul e and the reci rcul ati on
door motor.
F60 suppl i es power to the ATC modul e.
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.
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.
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.
rel ay, the contacts cl ose and connects ci rcui t F250
cl utch.
HELPFUL INFORMATION
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-
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
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
the ATC modul e.
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
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
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-43 AIRBAG SYSTEM
INDEX
page
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-43-2, 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
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
J978W-3 ZG004301
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 8W-43 AIRBAG SYSTEM 8W - 43 - 3
ZG004302 J978W-3
8W-43 AIRBAG SYSTEM
INDEX
page page
AIRBAG IMPACT SENSOR . . . . . . . . . . . . . . . . . 4
AIRBAG SQUIB (AIRBAG IGNITER) . . . . . . . . . . 4
AIRBAG WARNING LAMP . . . . . . . . . . . . . . . . . . 4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 4
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
Ci rcui t F20 connects to the ACM.
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.
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
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
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
J978W-3 ZG004401
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 8W-44 INTERIOR LIGHTING 8W - 44 - 3
ZG004402 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)
J978W-3 ZG004403
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)
ZG004404 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
F83
18
YL/DG
C15 3
OVERHEAD
CONSOLE OTHERS
F83
20
BK/VT
F83
20
YL/DG
F83
20
BK/VT
S323
F83
20
BK/VT
1
MIRROR
NIGHT
DAY/
AUTOMATIC
Z1
20
BK
FUSED
IGN.
(RUN)
OUTPUT
SWITCH
LAMP
BACK-UP
(8W-12-6)
(8W-10-8)
(8W-12-2)
(8W-12-6)
(8W-12-6)
(8W-12-7)
J978W-3 ZG004405
2
L10
BK/RD
20
GROUND
3
S322
(8W-12-6)
Z1
16
BK
MIRROR
NIGHT
DAY/
AUTOMATIC
(-)
DAY/
NIGHT
MIRROR
(+)
AUTOMATIC
DRIVER
POWER
MIRROR
(8W-62-4)
YL/BK
YL/BK
18
P114
20
18
P114
18
5
9
YL/BK
20
P114
A
3
4
C235
7
P112
YL/WT
20
C302
11
YL/WT
18
P112
C334
B
YL/WT
20
P112
C353
DAY/
NIGHT
MIRROR
(-)
AUTOMATIC AUTOMATIC
NIGHT
MIRROR
(+)
DAY/
B
(8W-44-7)
JUNCTION
TO
BLOCK
C
(8W-44-7)
BLOCK
JUNCTION
TO
A
(8W-44-7)
TO
PARK/
NEUTRAL
POSITION
SWITCH
SENSE
POWERTRAIN
CONTROL
MODUAL
Z1
16
BK
C5
4
C15 2
JUNCTION
BLOCK
Z1
18
BK
Z1
16
BK
Z1
16
BK
Z1
14
BK
Z1
14
BK
S220
S216
S202
2 C301
G304
(8W-12-22)
(8W-15-14)
(8W-15-14)
(8W-15-15)
(8W-15-15)
ZG004406 J978W-3
POSITION
NEUTRAL
PARK/
SWITCH
1
3
SWITCH
POSITION
NEUTRAL
PARK/
L10
18
BR/LG
C3
2
C15 7
6 C131
BR/LG
L10
18
2
L10
20
BK/RD
F83
YL/DG
18
S134
BK/WT
20
T41
BK/WT
18
T41
A6
C1
C
(8W-44-6)
FROM
S322
B
(8W-44-6)
C132
A
(8W-44-6)
FROM
MIRROR
NIGHT
DAY/
AUOMATIC
FROM
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
A
(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)
J978W-3 ZG004407
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)
ZG004408 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)
J978W-3 ZG004409
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)
ZG004410 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
A
(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)
J978W-3 ZG004411
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
ZG004412 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)
J978W-3 ZG004413
INDEX
page page
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
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.
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.
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.
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.
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
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
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
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
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
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
8W-45 BODY CONTROL MODULE
INDEX
page
Component Page
A/C Heater Control . . . . . . . . . . . . . . . . . . . 8W-45-9
Ash Lamp Recei ver . . . . . . . . . . . . . . . . . . 8W-45-10
Automati c Headl amp Li ght Sensor/Vtss
Led . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4
Automati c Temperature Control Modul e . . . 8W-45-9
Body Control Modul e . 8W-45-2, 3, 4, 5, 6, 7, 8, 9, 10
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
Dayti me Runni ng Lamp Modul e . . . . . . . . . 8W-45-5
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
Hood Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
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
Component Page
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
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
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
J978W-3 ZG004501
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 8W-45 BODY CONTROL MODULE 8W - 45 - 3
ZG004502 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)
J978W-3 ZG004503
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)
ZG004504 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)
J978W-3 ZG004505
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-53-3)
(8W-53-2)
ZG004506 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)
J978W-3 ZG004507
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
G9
16
GY/BK
G9
20
GY/BK
S117
G9
16
GY/BK
1
BRAKE
WARNING
SWITCH
SENSOR
TEMPERATURE
AMBIENT
A/C
AMBIENT
TEMPERATURE
SENSOR
SIGNAL
OTHERS
DRL
ATC
MANUAL A/C
ATC MANUAL
A/C
(8W-40-6)
(8W-40-6)
(8W-50-4)
(8W-42-6)
(8W-42-4)
(8W-42-5)
(8W-48-2)
ZG004508 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)
J978W-3 ZG004509
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)
ZG004510 J978W-3
INDEX
page page
A/C SELECT SWITCH . . . . . . . . . . . . . . . . . . . . 12
AJAR CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LOW FUEL WARNING LAMP ANNOUNCEMENT
CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LOW OIL PRESSURE WARNING CHIME . . . . . . 13
PARK LAMP SWITCH SENSE . . . . . . . . . . . . . . 13
SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . . . . 13
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)
Memory Seat Modul e
Passenger Door Modul e (PDM)
Powertrai n Control Modul e
Vehi cl e I nformati on Center
Radi o
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.
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
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.
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.
8W-46 MESSAGE CENTER
INDEX
page
Component Page
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
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-46-2, 3, 4, 5, 6
Lamp Outage Modul e . . . . . . . . . . . . . . . . . 8W-46-6
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
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
J978W-3 ZG004601
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 8W-46 MESSAGE CENTER
STANDARD
8W - 46 - 3
ZG004602 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-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)
OVERHEAD CONSOLE
ZG
J978W-3 ZG004603
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)
OVERHEAD CONSOLE
8W - 46 - 5
ZG004604 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)
OVERHEAD CONSOLE
ZG
J978W-3 ZG004605
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-30-18)
(8W-30-19)
(8W-30-19)
(8W-30-32)
(8W-30-18)
(8W-30-31)
(8W-45-2)
OVERHEAD CONSOLE
8W - 46 - 7
ZG004606 J978W-3
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 8
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.
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.
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.
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.
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
pl i es vol tage to the VI C.
the VI C.
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.
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.
connects ci rcui t G28 from the VI C to ground on ci r-
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
4WD posi ti on, i t connects ci rcui t T107 from the VI C
the 4WD di spl ay, the VI C al so i l l umi nates the PART
TI ME di spl ay.
posi ti on, i t connects ci rcui t T106 from the VI C to
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-
Z1. The VI C di spl ays the Low Cool ant Level warni ng
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.
8W-47 AUDIO SYSTEM
INDEX
page
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
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
J978W-3 ZG004701
C1
14
RADIO
12V
OUTPUT
POWER
AMPLIFIER
(LTD+)
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 8W-47 AUDIO SYSTEM
LTD AND POWER AMP
8W - 47 - 3
ZG004702 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
J978W-3 ZG004703
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
PREMIUM
8W - 47 - 5
ZG004704 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
LTD
ZG
J978W-3 ZG004705
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
PREMIUM
8W - 47 - 7
ZG004706 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
STANDARD
ZG
J978W-3 ZG004707
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)
LTD
8W - 47 - 9
ZG004708 J978W-3
C2
6
C2 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
8 C2
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)
PREMIUM
ZG
J978W-3 ZG004709
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
LTD
8W - 47 - 11
ZG004710 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-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-45-2)
(8W-45-7)
8W - 47 - 12 8W-47 AUDIO SYSTEM ZG
J978W-3 ZG004711
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 8W-47 AUDIO SYSTEM 8W - 47 - 13
ZG004712 J978W-3
8W-47 AUDIO SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 14
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
(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.
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-
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.
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
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.
Center (PDC) feeds the rel ay swi tch through fuse 13
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.
8W-48 REAR WINDOW DEFOGGER
INDEX
page
Component Page
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
Component Page
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-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
J978W-3 ZG004801
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
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.
8W-49 OVERHEAD CONSOLE
INDEX
page
Component Page
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
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
J978W-3 ZG004901
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 8W-49 OVERHEAD CONSOLE 8W - 49 - 3
ZG004902 J978W-3
OVERHEAD CONSOLE
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.
consol e l amps.
8W - 49 - 4 8W - 49 OVERHEAD CONSOLE ZG
8W-50 FRONT LIGHTING
INDEX
page
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
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
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Left Front Park Lamp . . . . . . . . . . . . . . . . . 8W-50-9
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Left Headl amp Level i ng Motor . . . . . . . . . 8W-50-11
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8W-50-7, 8
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
J978W-3 ZG005001
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-52-8)
(8W-15-6)
(8W-15-7)
(8W-52-8)
(8W-15-6)
(8W-15-7)
ZG 8W-50 FRONT LIGHTING 8W - 50 - 3
ZG005002 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)
J978W-3 ZG005003
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-45-5)
(8W-44-11) (8W-15-18)
(8W-10-11)
(8W-45-5)
(8W-45-5)
(8W-15-18)
ZG005004 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)
J978W-3 ZG005005
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)
ZG005006 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)
J978W-3 ZG005007
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)
ZG005008 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)
J978W-3 ZG005009
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)
ZG005010 J978W-3
INDEX
page page
AUTO HEADLAMPS . . . . . . . . . . . . . . . . . . . . . 12
FOG LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HEADLAMP LEVELING . . . . . . . . . . . . . . . . . . . 12
HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 12
PARKING LAMPS . . . . . . . . . . . . . . . . . . . . . . . 12
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
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).
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
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
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
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
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.
8W-51 REAR LIGHTING
INDEX
page
Component Page
Aftermarket Trai l er Tow Connector . . . . . . . 8W-51-6
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-51-5
Center Hi gh Mounted Stop Lamp No. 1 . 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
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
Trai l er Tow Stop Lamp Rel ay . . . . . . . . . . . 8W-51-3
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
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
J978W-3 ZG005101
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 8W-51 REAR LIGHTING 8W - 51 - 3
ZG005102 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)
J978W-3 ZG005103
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
9
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
3
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
1
F83
16
BACK-UP
LAMP
SWITCH
(8W-30-10)
(8W-44-6)
(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)
ZG005104 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)
J978W-3 ZG005105
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-12-14)
(8W-10-11)
(8W-12-2)
(8W-12-20)
(8W-10-9)
(8W-50-2)
(8W-50-5)
(8W-50-7)
(8W-15-18)
(8W-51-2)
(8W-51-3)
(8W-51-4)
(8W-51-5)
(8W-51-6)
(8W-15-18)
(8W-15-11) (8W-15-9)
(8W-15-11)
(8W-15-11)
ZG005106 J978W-3
8W-51 REAR LIGHTING
TAIL LAMPS, REAR LICENSE PLATE LAMPS AND
SIDE MARKER LAMPS
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
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
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
(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
Component Page
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
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-52-2, 4, 6, 7
Left Front Si de Marker Lamp . . . . . . . . . . . 8W-52-3
Left Front Turn Si gnal . . . . . . . . . . . . . . . . 8W-52-8
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 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
S408
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
F10 C234
L65
18
LG/DB
1 C102
L64
18
TN/DB
JUNCTION
BLOCK
C3
11
C4 5
1
C4
7
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
(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
J978W-3 ZG005201
G
(8W-52-8)
S412
TO
TN/DB
L64
18
GAS DIESEL
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)
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
(8W-15-4)
(8W-15-5)
(8W-12-15) (8W-12-15)
(8W-15-6)
(8W-15-7)
(8W-15-6)
(8W-15-7)
(8W-52-8)
ZG 8W-52 TURN SIGNALS 8W - 52 - 3
ZG005202 J978W-3
L64
18
TN/DB
L65
18
LG/DB
1 C102
GAS ENGINES
C234 F10
FROM
TURN
SIGNAL/
HAZARD
WARNING
SWITCH
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)
J978W-3 ZG005203
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 8W-52 TURN SIGNALS
FACTORY TRAILER TOW
8W - 52 - 5
ZG005204 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)
J978W-3 ZG005205
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-39-3)
(8W-12-2)
(8W-12-8)
ZG 8W-52 TURN SIGNALS
AFTERMARKET TRAILER TOW
8W - 52 - 7
ZG005206 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
S412
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
(8W-50-7)
(8W-50-8)
J978W-3 ZG005207
SWITCH
DIESEL ENGINES
8W-52 TURN SIGNALS
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.
Center (PDC) powers the el ectroni c fl asher through
fuse 13 i n the juncti on bl ock.
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.
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.
8W-53 WIPERS
INDEX
page
Component Page
Body Control Modul e . . . . . . . . . . . . . . . . 8W-53-2, 3
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 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
Wi ndshi el d Washer Pump Motor . . . . . . . . . 8W-53-2
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . 8W-53-2, 3
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
J978W-3 ZG005301
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 8W-53 WIPERS 8W - 53 - 3
ZG005302 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
J978W-3 ZG005303
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-45-11)
(8W-15-11)
(8W-15-11)
(8W-15-4)
(8W-15-5)
(8W-46-6)
(8W-15-4)
(8W-15-5)
ZG 8W-53 WIPERS 8W - 53 - 5
ZG005304 J978W-3
8W-53 WIPERS
INTERMITTENT WIPER OPERATION
swi tch connects ci rcui t A1 from fuse 8 i n the PDC to
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-
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
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.
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
Component Page
Aftermarket Trai l er Tow Connector . . . . . 8W-54-4, 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
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
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 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
B40
12
LB
B40
12
LB
B40
12
LB
8
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
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-44-6)
(8W-12-8)
(8W-12-8)
8W - 54 - 2 8W-54 TRAILER TOW ZG
J978W-3 ZG005401
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 8W-54 TRAILER TOW 8W - 54 - 3
ZG005402 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
J978W-3 ZG005403
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 8W-54 TRAILER TOW 8W - 54 - 5
ZG005404 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.
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.
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
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,
L61.
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
Component Page
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
J978W-3 ZG006001
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 8W-60 POWER WINDOWS 8W - 60 - 3
ZG006002 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
J978W-3 ZG006003
8W-60 POWER WINDOWS
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 5
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . 5
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
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
The PDM connects ci rcui t Q12 to ci rcui t F81 and
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.
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
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.
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.
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.
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.
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.
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
8W-61 POWER DOOR LOCKS
INDEX
page
Component Page
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
J978W-3 ZG006101
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 8W-61 POWER DOOR LOCKS 8W - 61 - 3
ZG006102 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
J978W-3 ZG006103
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 8W-61 POWER DOOR LOCKS 8W - 61 - 5
ZG006104 J978W-3
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
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.
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
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
Component Page
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . 8W-62-4
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
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
J978W-3 ZG006201
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 8W-62 POWER MIRRORS 8W - 62 - 3
ZG006202 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
J978W-3 ZG006203
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 8W-62 POWER MIRRORS 8W - 62 - 5
ZG006204 J978W-3
8W-62 POWER MIRRORS
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
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
reveres. The PDM suppl i es power to ci rcui t F73 and
Duri ng LEFT adjustments, the PDM suppl i es
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
Component Page
Ci rcui t Breaker 3 . . . . 8W-63-2, 3, 4, 8, 9, 10, 13, 14
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
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
J978W-3 ZG006301
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 8W-63 POWER SEAT 8W - 63 - 3
ZG006302 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)
J978W-3 ZG006303
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)
ZG006304 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
HORIZONTAL
MOTOR
DIVER DIVER
MOTOR
HORIZONTAL
(8W-63-5)
(8W-63-7) (8W-63-7)
(8W-63-5)
(8W-70-4)
J978W-3 ZG006305
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)
ZG006306 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)
J978W-3 ZG006307
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)
ZG006308 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)
J978W-3 ZG006309
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 8W-63 POWER SEAT
HEATED SEAT
8W - 63 - 11
ZG006310 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
J978W-3 ZG006311
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 8W-63 POWER SEAT
HEATED SEAT
8W - 63 - 13
ZG006312 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
J978W-3 ZG006313
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 8W-63 POWER SEAT
MEMORY SEAT
8W - 63 - 15
ZG006314 J978W-3
8W-63 POWER SEAT
INDEX
page page
HEATED SEATS . . . . . . . . . . . . . . . . . . . . . . . . 17
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 16
MEMORY SEATS . . . . . . . . . . . . . . . . . . . . . . . 17
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . 16
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.
to saved posi ti ons. The memory feature al so can set
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
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
For FRONT VERTI CAL DOWN functi on the ci r-
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.
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
ground.
8W - 63 - 16 8W - 63 POWER SEAT ZG
ground.
MEMORY SEATS
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
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
(PDC) powers ci rcui t F35 through the ci rcui t breaker.
ZG 8W - 63 POWER SEAT 8W - 63 - 17
connects ci rcui t A1 from fuse 8 i n the PDC to ci rcui t
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
8W-64 POWER SUNROOF
INDEX
page
Component Page
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
GY
F86
16
LG/BK
F86
16
LG/BK
F86
16
LG/BK
F86
16
RD/YL
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
(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
J978W-3 ZG006401
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 8W-64 POWER SUNROOF 8W - 64 - 3
ZG006402 J978W-3
8W-64 POWER SUNROOF
INDEX
page
POWER SUNROOF . . . . . . . . . . . . . . . . . . . . . . 4
POWER SUNROOF
Ci rcui t A31 powers ci rcui t F86 through the ci rcui t
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
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
Component Page
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 Sol enoi d . . . . . 8W-65-3
Steeri ng Wheel Speed Sensor . . . . . . . . . . . 8W-65-3
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
618
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
612
4
MODULE
STEERING
PROPORTIONAL
SPEED
(8W-10-8)
(8W-15-4)
(8W-15-5)
(8W-15-4)
(8W-15-5)
(8W-33-3)
(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
J978W-3 ZG006501
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 8W-65 SPEED PROPORTIONAL STEERING
GAS ENGINES
8W - 65 - 3
ZG006502 J978W-3
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPEED PROPORTIONAL STEERING CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPEED PROPORTIONAL STEERING
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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.
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.
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
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-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
J978W-3 ZG007001
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-30-6)
(8W-30-7)
(8W-30-8)
(8W-30-9)
(8W-30-13)
(8W-30-14)
(8W-30-16)
(8W-30-17)
(8W-30-10)
(8W-70-2)
(8W-31-3)
(8W-70-6)
(8W-30-16)
ZG 8W-70 SPLICE INFORMATION
GAS ENGINES
8W - 70 - 3
ZG007002 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
J978W-3 ZG007003
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
(8W-51-5) (8W-51-5)
(8W-33-2)
(8W-35-3)
(8W-51-3)
(8W-51-4) (8W-51-4)
(8W-51-3)
(8W-54-3)
(8W-54-4)
(8W-51-3) (8W-51-3)
(8W-51-5)
ZG 8W-70 SPLICE INFORMATION 8W - 70 - 5
ZG007004 J978W-3
WT/TN
WT/TN
C132
L50
18
9
L50
18
MSA
CONTROLLER
(8W-30-29)
20
S337
WT/TN
18
L50
WT/TN
18
L50
DIESEL GAS
GAS DIESEL
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-30-24)
(8W-30-28)
(8W-30-29)
(8W-70-9)
8W - 70 - 6 8W-70 SPLICE INFORMATION
GAS ENGINE
ZG
J978W-3 ZG007005
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)
DIESEL ENGINE
8W - 70 - 7
ZG007006 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)
DIESEL ENGINE
ZG
J978W-3 ZG007007
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)
DIESEL ENGINE
8W - 70 - 9
ZG007008 J978W-3
8W-80 CONNECTOR PIN-OUTS
INDEX
page
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
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 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
Horn No. 2. . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
Component Page
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 - 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
Left Rear Door Speaker . . . . . . . . . . . . . . . .8W-80-51
8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS ZG
Component Page
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 - C4 (Di esel ). . .8W-80-67
Radi o - C1 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-68
Component Page
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
Transmi ssi on Sol enoi d Assembl y . . . . . . . . .8W-80-79
Component Page
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
Vehi cl e Speed Sensor (Gas) . . . . . . . . . . . . .8W-80-80
Component Page
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 - 5 ZG 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZG008005

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
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
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 COMPRESSOR CLUTCH RELAY CONTROL
CAV
C3 18DB/BK*
C13 16DB**
C21 18DB/OR
A/C LOW PRESSURE
SWITCH
BLACK
2 1
1
1
2
* GAS
** DIESEL
J978W-3 ZG008006
BLACK
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
-
-
-
-
-
DRIVER AIRBAG LINE 2
PASSENGER AIRBAG LINE 1
GROUND
FUSED IGNITION SWITCH OUTPUT (RUN/START)
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
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
J978W-3 ZG008007
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 B(+)
BLEND AIR DOOR FEEDBACK SIGNAL
HIGH SPEED BLOWER MOTOR RELAY SIGNAL
RECIRCULATION DOOR MOTOR DRIVER
HIGH SPEED BLOWER MOTOR RELAY CONTROL
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
J978W-3 ZG008008
CIRCUIT
-
FUNCTION
-
5 VOLT SUPPLY
SENSOR RETURN
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
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
GROUND
CAV
1
2
C42 12RD
Z4 12BK
CIRCUIT FUNCTION
CAV
1
2
3
4
C4 14TN
C6 14LB
C7 12BK
C5 14LG
BLOWER MOTOR
(WITH AUTOMATIC
NATURAL
2 1
BLOWER MOTOR
RESISTOR BLOCK
(WITH MANUAL A/C-HEATER)
BLACK
2
3
1
4
J978W-3 ZG008009

CIRCUIT
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
WINDSHIELD WIPER SWITCH SIGNAL
SENSOR RETURN
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
FUSED IGNITION SWITCH OUTPUT (START/RUN)
CCD BUS (+)
CCD BUS (-)
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(+)
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
J978W-3 ZG008010
CIRCUIT
-
-
-
-
-
FUNCTION
-
-
-
-
-
ULTRALIGHT SENSOR DRIVER
RADIO CONTROL MUX
A/C SELECT INPUT
FUSED B(+)
ULTRALIGHT SENSOR SIGNAL
AUTO HEADLAMP RELAY CONTROL
HORN RELAY CONTROL
FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
PANEL LAMP DRIVER
WASHER SWITCH OUTPUT
WIPER SWITCH MODE SENSE
PANEL LAMP DIMMER SWITCH SIGNAL
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
J978W-3 ZG008011

CIRCUIT FUNCTION
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
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
J978W-3 ZG008012
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)
C132
(GAS)
J978W-3 ZG008013
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
J978W-3 ZG008014

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
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
BLACK
BLACK
BLACK
BLACK
J978W-3 ZG008015
* 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
J978W-3 ZG008016
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
J978W-3 ZG008017
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
J978W-3 ZG008018
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
ZG 8W - 80 - 19 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
J978W-3 ZG008020
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 ZG008021
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
J978W-3 ZG008022
CIRCUIT CAV
1
2
3
Q18 14GY/BK
Q28 14DG/WT
P34 14PK/BK
CIRCUIT
-
-
-
CAV
1
2
3
4
5
6
7
8
9
10
L90 18DB/RD
L10 18BR/LG
L61 18LG
L60 18TN
F70 18PK/BK
B40 12LB
Z1 12BK
CIRCUIT
-
-
-
CAV
1
2
3
4
5
6
7
8
9
10
L90 18DB/RD
L10 18BR/LG
L61 18LG/OR
L60 18TN/OR
F70 16PK/BK
B40 12LB
Z1 12BK
CIRCUIT CAV
1
2
3
Q18 16GY/BK
Q28 16DG/WT
P34 18PK/BK
C330
CIRCUIT CAV
1
2
3
4
5
6
F35 16RD
Z1 16BK
D1 18VT/BR
D2 18WT/BK
P7 18LB/BK*
F71 18PK/DG*
C329
CIRCUIT CAV
1
2
3
4
5
6
F35 14RD
Z1 14BK
D1 20VT/BR
D2 20WT/BK
P7 18LB/BK*
F87 18PK/DG*
C331
GRAY
BLACK
BLACK
GRAY
1 2
3
10
5
6
1
10
5
6
1
1 2
3
BLACK
BLACK
3 1
1
4
3
6
4 6
C329
C330
C331
CIRCUIT CAV
1
2
3
4
5
5
6
L73 18PK/WT
L21 18LB/WT
L10 18BR/LG
Z1 18BK
L61 18LG
L61 18LG
L36 18LG/OR
CIRCUIT CAV
1
2
3
4
5
6
L74 18PK/BK
L21 18LB/WT
L10 18BR/LG
Z1 18BK
L61 18LG
L36 18LG/BK
C328
C328
GRAY
4
6
1
3
GRAY
3
6
1
4
J978W-3 ZG008023

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
J978W-3 ZG008024
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
J978W-3 ZG008025

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
*
J978W-3 ZG008026

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
FUSED B(+)
CAV
A
B
C
M2 20YL
M1 20PK
M4 20WT/LG
BLACK
C A
CARGO LAMP
CIRCUIT FUNCTION
GROUND
GROUND
CAV
1
2
L87 20DG/WT
L87 20DG/WT
Z1 20BK
Z1 20BK
BLACK
NO. 1
1 2
CIRCUIT FUNCTION
GROUND
CAV
1
2
L87 20DG/WT
Z1 20BK
BLACK
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
J978W-3 ZG008027
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
GROUND
GROUND
CAV
1
2
L87 20DG/WT
L87 20DG/WT
Z1 20BK
Z1 20BK
BLACK
NO. 3
1 2
CIRCUIT FUNCTION
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
GROUND
SYSTEM RELAY
LEFT REAR WHEEL SPEED SENSOR (+)
LEFT FRONT WHEEL SPEED SENSOR (+)
G SWITCH SENSOR GROUND
ABS WARNING LAMP DRIVER
RIGHT REAR WHEEL SPEED SENSOR (+)
RIGHT FRONT WHEEL SPEED SENSOR (-)
SCI RECEIVE
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 16RD/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
J978W-3 ZG008028
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
CAV
1
2
3
K25 20WT/BK
K4 20BK/LB
K27 18RD/LG
(DIESEL)
(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
J978W-3 ZG008029

CIRCUIT FUNCTION
GROUND
FUSED B(+)
CAV
A
B
C
Z1 20BK
M2 2OYL
M1 20PK
DOME/READING
LAMP
NATURAL
A C
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
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
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
J978W-3 ZG008030
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
J978W-3 ZG008031

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
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
SENSOR GROUND
LUMBAR POSITION SENSE
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
J978W-3 ZG008032
CIRCUIT FUNCTION
LUMBAR REARWARD SWITCH SENSE
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
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
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
J978W-3 ZG008033

CIRCUIT FUNCTION
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
RECLINER DOWN SWITCH SENSE
FUSED B(+)
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 B(+)
HEATED SEAT DRIVER
GROUND
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
J978W-3 ZG008034
2 1
DRIVER SIDE
AIRBAG
YELLOW
CIRCUIT FUNCTION
DRIVER AIR BAG LINE 2
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
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
SENSOR GROUND
CAV
1
2
K2 16TN/BK
K4 16BK/LB
ENGINE COOLANT
TEMPERATURE SENSOR
(WITH 4.OL ENG)
CIRCUIT FUNCTION
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
J978W-3 ZG008035
* GAS
** DIESEL
CIRCUIT FUNCTION
B(+)
B(+)
CAV
1
1
2
2
A0 6RD
A0 2RD**
T40 12LG/BK
T40 14LG/BK**
ENGINE STARTER MOTOR
BLACK
1
2
CIRCUIT
-
FUNCTION
-
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
FUSED B(+)
LEFT TURN SIGNAL
RIGHT TURN SIGNAL
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
J978W-3 ZG008036
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
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
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
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
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
J978W-3 ZG008037

CIRCUIT FUNCTION
G SWITCH GROUND
CAV
1
2
3
B43 20PK/OR
B41 20YL/VT
B42 20TN/WT
G-SWITCH
CIRCUIT
-
FUNCTION
-
GENERATOR FIELD DRIVER
CAV
1
2
3
A142 16DG/OR
K20 18DG/YL
GENERATOR
(DIESEL)
CIRCUIT
-
FUNCTION
-
GROUND
CAV
1
2
3
4
Z0 8BK
K72 18DG/VT
K20 18DG
GENERATOR
(GAS)
CIRCUIT FUNCTION
BATTERY POSITIVE
GLOW PLUG RELAY CONTROL SENSE
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
1
2
3
4
5
6
7
8
J978W-3 ZG008038
CIRCUIT
-
-
-
FUNCTION
-
-
-
ENGINE COOLANT LEVEL SWITCH SENSE
FUSED B(+)
GROUND
TURN SIGNAL
REAR LAMP OUT INDICATOR DRIVER
CCD BUS (+)
CCD BUS (-)
PANEL LAMP DRIVER
WASHER FLUID LEVEL SENSE
4-WHEEL DRIVE PART TIME LAMP
4-WHEEL DRIVE FULL 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
J978W-3 ZG008039
CIRCUIT
-
-
-
FUNCTION
-
-
-
PANEL LAMP DRIVER
GROUND
FOG LAMP RELAY OUTPUT
GROUND
COIL DRIVER #6
FUSED B(+)
LOW HEADLAMP SWITCH SENSE
PARK LAMP FEED
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
J978W-3 ZG008040
CIRCUIT FUNCTION
IDLE AIR CONTROL NO. 1 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
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
CAV
1
2
K19 18GY/WT
A142 18DG/OR
IGNITION COIL
1
BLACK
2
CIRCUIT FUNCTION
IGNITION SWITCH OUTPUT (START)
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
SENSOR GROUND
CAV
A
B
C10 20RD/TN
D41 20LG/WT
IN-CAR TEMPERATURE
SENSOR
BLACK
B
J978W-3 ZG008041

CIRCUIT FUNCTION
INJECTOR NO.1 DRIVER
CAV
1
2
A142 18DG/OR
K11 18WT/DB
CIRCUIT FUNCTION
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
CAV
1
2
A142 18DG/OR
K13 18YL/WT
GRAY
2
FUEL INJECTOR
NO.3
1
CIRCUIT FUNCTION
CAV
1
2
A142 18DG/OR
K14 18LB/BR
GRAY
2
FUEL INJECTOR
NO.4
1
CIRCUIT FUNCTION
CAV
1
2
A142 18DG/OR
K38 18GY
GRAY
2
FUEL INJECTOR
NO.5
1
J978W-3 ZG008042
CIRCUIT FUNCTION
CAV
1
2
A142 18DG/OR
K58 18BR/YL
GRAY
2
FUEL INJECTOR
NO.6
1
CIRCUIT FUNCTION
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(+)
FUSED B(+)
FUSED B(+)
PARK LAMP SWITCH OUTPUT
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
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(+)
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
J978W-3 ZG008043

JUNCTION BLOCK - C3
CIRCUIT
-
-
-
-
FUNCTION
-
-
-
-
HORN RELAY CONTROL
2-WHEEL DRIVE LAMP/LOW RANGE
FUSED B(+)
FUSED B(+)
TURN SIGNAL SWITCH OUTPUT
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
-
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
AUTO HEADLAMP RELAY OUTPUT
FUSED B(+)
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
FUSED B(+)
FUSED B(+)
FUSED B(+)
CAV
1
2
3
4
A21 12DB/GY
A7 12YL/RD
A900 12OR/YL
A250 10RD
J978W-3 ZG008044
JUNCTION BLOCK - C6
3
1
4
2
BLACK
CIRCUIT FUNCTION
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
-
-
FLASH TO PASS
HAZARD SIGNAL
REAR FOG LAMP
GROUND
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 B(+)
FUSED B(+)
FUSED B(+)
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
J978W-3 ZG008045

8
3
1
12
7
2
JUNCTION BLOCK - C9
LIGHT
GRAY
CIRCUIT
-
-
-
FUNCTION
-
-
-
REAR WINDOW DEFOGGER LAMP DRIVER
FUSED B(+)
FUSED B(+)
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
-
-
FUSED B(+)
HORN 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
CAV
1
2
3
X17 20DG
X14 20WT
X16 20GY
BLACK
1
3
2
* AUTOMATIC TEMP CONTROL
2
7
12
3
8
1
JUNCTION BLOCK
BODY CONNECTOR - C13
NATURAL
CIRCUIT
-
-
-
-
-
FUNCTION
-
-
-
-
-
FUSED B(+)
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
J978W-3 ZG008046
BLACK
1
3 6
7 10
2
JUNCTION BLOCK
CIRCUIT
-
-
FUNCTION
-
-
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 B(+)
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
(OVERHEAD CONSOLE)
BLACK
CIRCUIT FUNCTION
GROUND
FUSED B(+)
CAV
1
2
3
4
Z1 20BK
G26 20LB
M2 20YL
M1 20PK
GRAY
KEY-IN SWITCH/
HALO LAMP
1 4
J978W-3 ZG008047

CIRCUIT
-
FUNCTION
-
NOT USED
NOT USED
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
CIRCUIT FUNCTION
NOT USED
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
CAV
1
2
R47 18DB/LB
R49 18LB
LEFT AIRBAG
SENSOR
BLACK
1 2
J978W-3 ZG008048
CIRCUIT FUNCTION
GROUND
CAV
A
G
L10 18BR/LG
Z1 18BK
BLACK
LEFT BACK-UP LAMP
A
G
CIRCUIT FUNCTION
FUSED B(+)
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
J978W-3 ZG008049

CIRCUIT FUNCTION
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
CAV
1
2
Q11 16LB
Q21 16WT
BLACK
LEFT FRONT POWER
WINDOW MOTOR
2 1
CIRCUIT FUNCTION
GROUND
CAV
A
B
L90 18DB/RD
Z1 18BK
WHITE
LEFT FRONT PARK LAMP
B A
CIRCUIT FUNCTION
CAV
A
B
L90 18DB/RD
L64 18TN/DB
GRAY
LEFT FRONT SIDE MARKER LAMP
B A
J978W-3 ZG008050
BLACK
LEFT FRONT TURN
SIGNAL LAMP
A
G
CIRCUIT FUNCTION
GROUND
CAV
A
G
L64 18TN/DB
Z1 18BK
CIRCUIT FUNCTION
LEFT FRONT WHEEL SPEED SENSOR (-)
CAV
1
2
B8 20RD/DB
B9 20RD
LEFT FRONT
WHEEL SPEED SENSOR
BLACK
2 1
CIRCUIT FUNCTION
GROUND
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
J978W-3 ZG008051

CIRCUIT FUNCTION
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
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
J978W-3 ZG008052
CIRCUIT FUNCTION
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
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
GROUND
CAV
A
G
L60 18TN
Z1 18BK
BLACK
LEFT REAR TURN
SIGNAL LAMP
A
G
CIRCUIT FUNCTION
CAV
A
B
B3 20LG/DB
B4 20LG
LEFT REAR WHEEL
SPEED SENSOR
B A
BLACK
CIRCUIT FUNCTION
CAV
1
2
Q12 16BR
Q22 16VT
2
LEFT REAR POWER
WINDOW MOTOR
BLACK
1
1
2
J978W-3 ZG008053

CIRCUIT FUNCTION
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
BLACK
3
CIRCUIT FUNCTION
VTSS DISARM SENSE
GROUND
CAV
1
2
G71 20VT/YL
Z1 20BK
1
LIFTGATE
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
J978W-3 ZG008054
CIRCUIT
-
FUNCTION
-
GROUND
LIFTGLASS AJAR SWITCH SENSE
CAV
1
2
3
Z1 20BK
G78 20TN/BK
1
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
CAV
1
2
P100 14OR/BR
P101 16OR/PK
1
LIFTGLASS PUSH BUTTON
BLACK
2
CIRCUIT FUNCTION
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
J978W-3 ZG008055

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
CONT SLEEVE POS SENSE
NEEDLE MOVE SENSOR (-)
NEEDLE MOVE SENSOR (+)
ENGINE COOLANT TEMPERATUR SENSOR SIGNAL
THROTTLE POSITION SENSOR SIGNAL
POWER GROUND
EGR SOLENOID CONTROL
FLT SIGNAL
COIL DRIVER #2
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 TIMING SHUTOFF 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 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZG008056
CIRCUIT
-
FUNCTION
-
SENSOR GROUND
RECLINER POSITION 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
GROUND
FUSED B(+)
FUSED B(+)
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
J978W-3 ZG008057

CIRCUIT FUNCTION
GROUND
CCD BUS(+)
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
5 VOLT SUPPLY
SENSOR RETURN
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 HIGH SPEED OUTPUT
WIPER SWITCH LOW SPEED OUTPUT
HAZARD SIGNAL
TURN SIGNAL
TURN SIGNAL
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
J978W-3 ZG008058
CIRCUIT FUNCTION
SENSOR GROUND
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
GROUND
CCD BUS(+)
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
J978W-3 ZG008059

CIRCUIT FUNCTION
PARK/NEUTRAL POSITION SWITCH SENSE
CAV
1
2
3
L10 18BR/LG
T41 20BK/WT
F83 18YL/DG
BLACK
PARK/NEUTRAL POSITION
SWITCH
1 3
CIRCUIT FUNCTION
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
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
SENSOR GROUND
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
J978W-3 ZG008060
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
CAV
1
2
P106 18DG/WT
P107 18OR/BK
BLACK
PASSENGER
LUMBAR MOTOR
1 2
CIRCUIT FUNCTION
GROUND
FUSE B(+)
GROUND
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
J978W-3 ZG008061

CIRCUIT FUNCTION
CAV
1
2
P20 16RD/LG
P18 16YL/LG
RED
PASSENGER POWER SEAT
FRONT RISER MOTOR
1 2
CIRCUIT FUNCTION
CAV
1
2
P14 16YL/LB
P16 16RD/LB
BLACK
HORIZONTAL MOTOR
1 2
CIRCUIT FUNCTION
CAV
1
2
P12 16RD/WT
P10 16YL/WT
RED
REAR RISER MOTOR
1 2
CIRCUIT FUNCTION
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
FUSED B(+)
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
J978W-3 ZG008062
PASSENGER SEAT HEATER
CONTROL MODULE
CIRCUIT
-
-
-
FUNCTION
-
-
-
FUSED B(+)
HEATED SEAT DRIVER
GROUND
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 (+)
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(+)
LEFT REAR (+)
LEFT FRONT (+)
AMPLIFIED LEFT REAR (-)
FUSED B(+)
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
WHITE
10
1
5
7
6
14
CIRCUIT FUNCTION
5 VOLT SUPPLY
SENSOR GROUND
CAV
3
5
7
8
10
K255 20WT/DG
K151 20WT
K6 20VT/WT
K4A 18BK/LB
K22 20OR/DB
(DIESEL)
1 6
5 10
J978W-3 ZG008063

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 GROUND
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(+)
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
J978W-3 ZG008064
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
1
2
F38 18OR
Z1 18BK
POWER OUTLET
BLACK
2
1
SENSOR GROUND
5 VOLT SUPPLY
FUSED B(+)
UPSTREAM 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
J978W-3 ZG008065

TRANSMISSION TEMPERATURE SENSOR SIGNAL
VARIABLE FORCE SOLENOID CONTROL
TORQUE CONVERTER CLUTCH SOLENOID CONTROL
OVERDRIVE SOLENOID CONTROL
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 18BR/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
J978W-3 ZG008066
AUTOMATIC SHUT DOWN RELAY CONTROL
SPEED CONTROL VACUUM SOLENOID CONTROL
SPEED CONTROL VENT SOLENOID CONTROL
OVERDRIVE OFF LAMP DRIVER
OVERDRIVE OFF 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
J978W-3 ZG008067

LOW FUEL WARNING
FUSED B(+)
SENSOR GROUND
5 VOLT SUPPLY
GROUND
GROUND
WATER-IN-FUEL SENSE
DISTRIBUTOR PICK-UP SIGNAL
SCI RECEIVE
CCD BUS(+)
WAIT TO START LAMP
SCI TRANSMIT
CCD BUS(-)
ENGINE COOLANT LEVEL SIGNAL
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)
BLACK
41 21 1
60 40 20
J978W-3 ZG008068
CIRCUIT
-
FUNCTION
-
LEFT FRONT (-)
RIGHT FRONT (-)
PANEL LAMP DRIVER
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
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
J978W-3 ZG008069

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)
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
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
-
-
CAV
1
2
3
4
5
C33 20VT/OR
C32 20LB/DG
F71 20PK/DG
RECIRCULATION DOOR
ACTUATOR
(WITH AUTOMATIC
YELLOW
1 2 3 4 5
J978W-3 ZG008070
CIRCUIT FUNCTION
RIGHT IMPACT SENSOR LINE 1
CAV
1
2
R46 18BR/LB
R48 18TN
RIGHT AIRBAG
SENSOR
BLACK
2 1
CIRCUIT FUNCTION
GROUND
CAV
A
G
L10 18BR/LG
Z1 18BK
BLACK
RIGHT BACK-UP LAMP
A
G
CIRCUIT FUNCTION
FUSED B(+)
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
CAV
1
2
Z1 18BK
L39 18LB
RIGHT FOG LAMP
1 2
BLACK
J978W-3 ZG008071

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
GROUND
CAV
A
B
L90 18DB/RD
Z1 18BK
WHITE
RIGHT FRONT PARK LAMP
B A
CIRCUIT FUNCTION
CAV
1
2
Q12 16BR
Q22 16VT
BLACK
RIGHT FRONT POWER
WINDOW MOTOR
2 1
8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZG008072
CIRCUIT FUNCTION
CAV
A
B
L90 18DB/RD
L64 18TN/DB
GRAY
RIGHT FRONT SIDE MARKER LAMP
B A
CIRCUIT FUNCTION
GROUND
CAV
A
G
L64 18TN/DB
Z1 18BK
BLACK
RIGHT FRONT TURN
SIGNAL LAMP
A
G
CIRCUIT FUNCTION
CAV
1
2
B6 20WT/DB
B7 20WT
RIGHT FRONT
WHEEL SPEED
SENSOR
1
BLACK
2
CIRCUIT FUNCTION
GROUND
CAV
1
2
3
Z1 16BK
L4 16VT/OR
L3 16RD/OR
BLACK
RIGHT HEADLAMP
1
2
3
CIRCUIT FUNCTION
CAV
A
B
X82 20LB/RD
X80 20LB/BK
RIGHT INSTRUMENT
PANEL SPEAKER
BLACK
A B
EXPORT

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
RIGHT HEADLAMP
LEVELING MOTOR
BLACK
ZG
J978W-3 ZG008073

CIRCUIT FUNCTION
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
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
GROUND
CAV
1
2
3
L64 18TN/DB
L90 18DB/RD
Z1 18BK
RIGHT PARK TURN
SIGNAL MARKER
2 1
3
J978W-3 ZG008074
CIRCUIT FUNCTION
GROUND
CAV
1
2
Z1 18BK
L22 18LB
NATURAL
RIGHT REAR SIDE
MARKER LAMP
1 2
CIRCUIT FUNCTION
GROUND
CAV
A
G
L61 18LG
Z1 18BK
BLACK
RIGHT REAR TURN
SIGNAL LAMP
A
G
FUNCTION CIRCUIT
CAV
A
B
B1 20YL/DB
B2 20YL
RIGHT REAR WHEEL
SPEED SENSOR
A B
RED
CIRCUIT FUNCTION
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
CAV
1
2
Q12 16BR
Q22 16VT
2
RIGHT REAR POWER
WINDOW MOTOR
BLACK
1
J978W-3 ZG008075

CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
A
B
M1 20PK
Z1 20BK
A
RIGHT VISOR/
VANITY MIRROR
BLACK
B
CIRCUIT FUNCTION
GROUND
CAV
1
2
G10 20LG/RD
Z1 20BK
SEAT BELT
SWITCH
CIRCUIT FUNCTION
SHIFT INTERLOCK SOLENOID SENSE
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
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
J978W-3 ZG008076
SPEED PROPORTIONAL
STEERING MODULE
GREEN
CIRCUIT
-
-
-
FUNCTION
-
-
-
SPEED PROPORTIONAL STEERING SOLENOID CONTROL
LOW
HIGH
STEERING WHEEL SPEED SENSOR GROUND
5 VOLT SUPPLY
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
J978W-3 ZG008077

STEERING WHEEL
SPEED SENSOR
CIRCUIT FUNCTION
5 VOLT SUPPLY
CAV
A
B
C
D
S1 20BK/YL
S2 20BK/LG
S3 20PK/WT
S4 20VT
A D
NATURAL
CIRCUIT
-
FUNCTION
-
GROUND
PANEL LAMP DRIVER
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
CAV
1
2
3
4
Z1 16BK
Q41 18WT
Q42 18LB
F86 18LG/BK
SUNROOF CONTROL
MODULE
CIRCUIT FUNCTION
GROUND
SPEED CONTROL 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
J978W-3 ZG008078

CIRCUIT FUNCTION
5 VOLT SUPPLY
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

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
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
J978W-3 ZG008079

CIRCUIT FUNCTION
GROUND
FUSED B(+)
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
TORQUE CONVERTER CLUTCH SOLENOID OUTPUT
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
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
J978W-3 ZG008080
CIRCUIT FUNCTION
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
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
-
-
-
FUSED B(+)
GROUND
TURN SIGNAL
CCD BUS (+)
CCD BUS (-)
PANEL LAMP DRIVER
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
J978W-3 ZG008081

CIRCUIT FUNCTION
GROUND
CAV
A
B
V11 18TN/BK
Z2 18BK
CIRCUIT
-
FUNCTION
-
GROUND
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
GROUND
CAV
A
B
G29 16BK/TN
Z2 16BK
WIPER
FLUID LEVEL
SENSOR
BLACK
B A
CIRCUIT FUNCTION
8 VOLT SUPPLY
SENSOR GROUND
CAV
1
2
3
K7 20OR
K167 20BR/YL
G7 20WT/OR
VEHICLE SPEED
SENSOR
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
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.
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 N/S
A/C High
Pressure Switch
BK Near A/C
Compressor
6, 8,
11
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
19
Airbag Control
Module C2
YL Below Center
Floor Console,
Near Park Brake
19
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
18
Automatic
Temperature
Control Module
BK Left Side of
HVAC Housing
N/S
Battery
Temperature
Sensor
BK Below Battery
Tray
4
Blend Air Door
Motor
BK On Bottom of
HVAC Unit
N/S
Blend Air
Actuator
BK On Bottom of
HVAC Unit
N/S
Connector
Name/Number
Color Location Fig.
Blower Motor NAT Right Side of
HVAC
N/S
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
16
Body Control
Module C2
WT Lower Left of
Instrument Panel
16
Body Control
Module C3
BK Lower Left of
Instrument Panel
16
Brake Warning
Switch
BK Right Fender
Side Shield,
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 Right Rear
Corner of Engine
Compartment At
PCM
N/S
C144 BK Below PDC 6, 12
C150 BK Rear of Fog
Lamp
1
C160 BK Right Corner of
Instrument Panel
15
ZG 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 1
Connector
Name/Number
Color Location Fig.
C206 BK On Front of
HVAC Unit
15
C212 RD Center of
Instrument Panel
14
C213 GN Behind Right
Kick Panel, At
Junction Block
15
C231 BK Right End of
Instrument Panel
N/S
C233 BK Lower Left of
Instrument
Panel, In
Connector
Bracket
16
C234 WT Lower Left of
Instrument
Panel, In
Connector
Bracket
16
Instrument
Panel, In
Connector
Bracket
16
Instrument
Panel, In
Connector
Bracket
16
C300 YL Lower Left of
Instrument Panel
16
C301 NAT Lower Left of
Instrument
Panel, In
Connector
Bracket
16
Instrument
Panel, In
Connector
Bracket
16
C304 GY Lower Left of
Instrument Panel
N/S
Instrument
Panel, In
Connector
Bracket
16
Instrument Panel
16
Connector
Name/Number
Color Location Fig.
C309 GY In Left Rear
Door
22
C320 GY Right Rear
Quarter Panel,
Near Bottom of
Liftgate Opening
19
C321 BK In Liftgate 24
C322 GN In Liftgate 24
C323 GY In Liftgate 24
C328 GY Left Rear
Quarter Panel,
Near Bottom of
Liftgate Opening
20
C329 BK Below Left Rear
Passenger Seat
20
C330 GY In Right Rear
Door
22
C334 BK In Left Front
Door
21
Passenger Seat
19
C343 BK In Left Rear
Door
22
C345 BK In Right Rear
Door
22
C351 GY In Right Front
Door
21
C353 BK In Left Front
Door
21
C372 BK Right Rear
Quarter Panel
23
(Diesel)
11
C907 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
20
8W - 90 - 2 8W - 90 CONNECTOR LOCATIONS ZG
Connector
Name/Number
Color Location Fig.
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 Left of
Instrument Panel
14
Daytime Running
Lamp Module
BK Right Fender
Side Shield,
Below PDC
2
Dome/Reading
Lamp
NAT Behind Dome
Lamp
18
Downstream
Heated Oxygen
Sensor
BK Above Rear of
Catalytic
Converter
7, 10
Driver Door
Module C1
WT In Left Front
Door
21
Driver Door
Module C2
BK In Drivers Door N/S
Driver Door
Module C3
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
Connector
Name/Number
Color Location Fig.
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 Left of
Instrument Panel
16, 17
Duty Cycle
EVAP/Purge
Solenoid
BK Front of Left
Fender Side
Shield
3
Engine Coolant
Level Sensor
BK Right Rear
Corner of Engine
Compartment
2
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
3
Factory Trailer
Tow Connector
BK On Trailer Hitch 23
Connector
Name/Number
Color Location Fig.
Floor Console
Lamps
BK Left Side of
Center Floor
Console
19
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 19
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
6, 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
G108 Front of Left
Fender Side
Shield
3
G109 Front of Left
Fender Side
Shield
3
G300 Right Rear
Quarter Panel
19
Connector
Name/Number
Color Location Fig.
G301 Rear of
Passengers
Seat
19
G302 On Floor Pan
Rear of Drivers
Seat
20
G303 On Floor Pan
Rear of Drivers
Seat
20
G304 On Floor Pan
Rear of Drivers
Seat
20
G305 On Floor Pan
Rear of Drivers
Seat
20
G-Switch BK Below Right
Rear Passenger
Seat
19
Generator BK At Generator 6
Glove Box Lamp BK At Glove Box
Lamp
14
Glow Plug Relay BK At PDC (Diesel
Engine)
N/S
Graphic Display
Module/Vehicle
Information
Center
BK Rear of Vehivle
Information
Center (VIC)
11
Headlamp
Leveling Switch
BK At Switch N/S
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
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
17
Connector
Name/Number
Color Location Fig.
In-Car
Temperature
Sensor
BK Center, Top of
Instrument Panel
14
Injector No. 1 GY At Injector 5, 9
Injector No. 7 GY At Injector 9
Instrument
Cluster
BK Rear of
Instrument
Cluster
14
Intake Air
Temperature
Sensor
GY On Intake
Manifold
5, 8
Junction Block -
C1
BK Behind Right
Kick Panel
15
Junction Block -
C2
BK Behind Right
Kick Panel
15
Junction Block -
C3
BK Behind Right
Kick Panel
15
Junction Block -
C4
BL* Behind Right
Kick Panel
15
Junction Block -
C5
YL Behind Right
Kick Panel
15
Junction Block -
C6
GY Behind Right
Kick Panel
15
Junction Block -
C7
GN Behind Right
Kick Panel
15
Junction Block -
C8
BK Behind Right
Kick Panel
N/S
Junction Block -
C9
BK Behind Right
Kick Panel
N/S
Junction Block -
C10
BK Behind Right
Kick Panel
N/S
Junction Block
Body Connector -
C13
BK Behind Right
Kick Panel
N/S
Junction Block
Body Connector -
C14
BK Behind Right
Kick Panel
N/S
Key-In Switch/
Halo Lamp
GY On Steering
Column, Near
Ignition Switch
17
Connector
Name/Number
Color Location Fig.
Lamp Outage
Module C1
BK Left Rear
Quarter Panel,
Near Bottom of
Liftgate Opening
20
Lamp Outage
Module C2
BK Left Rear
Quarter Panel,
Near Bottom of
Liftgate Opening
20
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
21
Left Fog Lamp BK Left Fog Lamp 1
Left Front
Cylinder Lock
Switch
BK In Left Front
Door
21
Left Front Door
Lock Motor
BK In Left Front
Door
21
Left Front Door
Speaker
BK In Left Front
Door
21
Left Front Park
Lamp
WT At Lamp N/S
Left Front Power
Window Motor
BK In Left Front
Door
21
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
3
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
26
Left Rear Door
Lock Motor
BK In Left Rear
Door
22
Left Rear Door
Speaker
BK In Left Rear
Door
22
Connector
Name/Number
Color Location Fig.
Left Rear Power
Window Motor
BK In Left Rear
Door
22
Left Rear Power
Window switch
BL In Left Rear
Door
22
Left Rear Side
Marker Lamp
NAT At Lamp N/S
Left Rear Turn
Signal Lamp
BK At Lamp N/S
Left Rear Wheel
Speed Sensor
BK Below Right
Rear Passenger
Seat
19
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
18
Liftgate Ajar
Switch
BK In Liftgate 24
Liftgate Cylinder
Lock Switch
BK In Liftgate 24
Liftgate Lock
Motor
BK In Liftgate 24
Liftglass Ajar
Switch
BK In Liftgate 24
Liftglass Limit
Switch
NAT In Liftgate 24
Liftglass Push
Button
BK In Liftgate 24
Liftglass Release
Solenoid
BK In Liftgate 24
Low Washer
Fluid Level
Sensor
BK Below Battery
Tray
4
Manifold Absolute
Pressure Sensor
Memory Seat
Module
Connector C1
BK At Drivers Seat N/S
Memory Seat
Module
Connector C2
Mini Overhead
Console
GY Under
Passengers
Seat
N/S
Mode Door Motor BK Left Side of
HVAC
N/S
Connector
Name/Number
Color Location Fig.
Multi-Function
Switch
BK On Steering
Column
17
Oil Pressure
Sensor
Output Shaft
Speed Sensor
BK Left Side of
Transmission
7, 10
Overhead
Console
RD Center of
Headliner, Above
Rear View Mirror
18
Overhead
Console Junction
Block
BK Behind Right
Kick Panel, At
Junction Block
15
Park/Neutral
Position Switch
BK Left Side of
Transmission
7, 10
Passenger Airbag YL Behind
Passenger
Airbag
14
Passenger Door
Module
WT In Right Front
Door
21
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
Connector
Name/Number
Color Location Fig.
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 Junction
Block
N/S
Power Outlet BK Rear of Power
Outlet
14
Powertrain
Control Module
C1
BK Right Rear
Corner of Engine
Compartment At
PCM
2
Powertrain
Control Module
C2
WT Right Rear
Corner of Engine
Compartment At
PCM
2
Powertrain
Control Module
C3
GY Right Rear
Corner of Engine
Compartment At
PCM
2
Radio C1 GY Rear of Radio 14
Radio C2 BK Rear of Radio 14
Rear Speaker BK Rear Door 22
Rear Washer
Pump Motor
BK lBottom of
Windshield
Washer Fluid
Reservoir
4
Rear Wiper
Motor
BK In Liftgate 24
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
21
Right Fog Lamp BK Rear of Fog
Lamp
1
Connector
Name/Number
Color Location Fig.
Right Front
Cylinder Lock
Switch
BK In Right Front
Door
21
Right Front Door
Lock Motor
BK In Right Front
Door
21
Right Front Door
Speaker
BK In Right Front
Door
21
Right Front Park
Lamp
WT At Lamp N/S
Right Front
Power Window
Motor
BK In Right Front
Door
21
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
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
26
Right Rear Door
Lock Motor
BK In Right Rear
Door
22
Right Rear Door
Speaker
BK In Right Rear
Door
22
Right Rear
Power Window
Motor
BK In Right Rear
Door
22
Right Rear
Power Window
Switch
BL In Right Rear
Door
22
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
19
Right Side
Repeater Lamp
BK At Lamp N/S
Connector
Name/Number
Color Location Fig.
Right Tail/Stop
Lamp
BK At Lamp N/S
Right Visor/Vanity
Mirror
BK Top of Right
A-Pillar
18
Seat Belt Switch BK Near Bottom of
Drivers Seat
Belt Clasp
19
Shift Interlock BK Steering
Column, On Shift
Cable
N/S
Solar Sensor RD Above Glove
Box
14
Speed
Proportional
Steering Control
Module
GN Top Left Corner
of Dash Panel,
Behind
Instrument Panel
16
Speed
Proportional
Steering Solenoid
BK On Power
Steering Pump
3, 5
Steering Wheel
Speed Sensor
RD Above Glove
Box
14
Stop Lamp
Switch
GY Top of Brake
Pedal Arm
16
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
18
Switch Pod BK Rear of
Overdrive Switch
14
Connector
Name/Number
Color Location Fig.
Throttle Position
Sensor
Trailer Tow
Circuit Breaker
BK Right Rear
Quarter Panel
23
Trailer Tow Left
Turn Relay
BK Right Rear
Quarter Panel
23
Trailer Tow Right
Turn Relay
BK Right Rear
Quarter Panel
23
Trailer Tow Stop
Lamp Relay
BK Right Rear
Quarter Panel
23
Transmission
Solenoid
Assembly
BK Left Side of
Transmission
7, 10
Underhood Lamp BK On Underside of
Hood
25
Upstream Heated
Oxygen Sensor
GY Right Front of
Transmission
10
Vehicle Speed
Control Servo
BK Right Fender
Side Shield
2
Vehicle Speed
Control/Horn
Switch
NAT On Steering
Column
17
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
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Fig. 26 License Plate Lamps
8W-95 SPLICE LOCATIONS
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
S104 Right Front Corner of Engine
Compartment
1
Compartment
1
Compartment
1
S107 Left Front Corner of Engine
Compartment
1
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
T/O
1
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
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 Rear of Engine (Diesel Engine) N/S
S130 Near Crankshaft Position Sensor T/O
(5.2L Engine)
3
(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
S133 In Branch to Oil Pressure Sensor and
Crankshaft Position Sensor (4.0L
Engine)
2
S134 Near Branch to Powertrain Control
Module (4.0L Engine)
2
(Diesel Engine)
4
S135 Near Branch to PCM (4.0L Engine) 2
S135 Right Rear of Engine (5.2L Engine) 3
(Diesel Engine)
4
(Diesel Engine)
4
S140 Rear of Engine (Diesel Engine) 4
ZG 8W - 95 SPLICE LOCATIONS 8W - 95 - 1
Splice
Number
Location Fig.
S200 Near Headlamp Switch T/O 5
S202 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
Module/Vehicle Information Center
5
S221 On HVAC Harness 7
S300 Near Left Kick Panel 6
S303 Near Branch to Floor Console 8
S305 Near Branch to Left Rear Door 8
S308 Near Branch to Power Amplifier 8
S309 In Branch to Power Amplifier 8
S311 Left Rear Quarter Panel 8
Splice
Number
Location Fig.
S314 Top of Left Rear Quarter Panel 8
S316 Near Right Side T/O for Liftgate 9
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
Window Motor T/O
11
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
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
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
Seat Switch T/O
N/S
8W - 95 - 2 8W - 95 SPLICE LOCATIONS ZG
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
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
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
N/S
S417 In Right Tail Lamp Harness, Between
N/S
S418 In License Plate Lamp Harness 12
S419 In License Lamp Harness 12
S421 Fuse Link at PDC N/S
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Fig. 6 Body Splices
Fig. 7 HVAC Harness Splices
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Fig. 10 Roof Wiring Splices
Fig. 11 Front Door Harness Splices
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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
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
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
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . 7
TERMINAL/CONNECTOR REPAIRTHOMAS
AND BETTS CONNECTORS . . . . . . . . . . . . . . 8
WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . 11
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.
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
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
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
Fig. 5 Symbol Identification
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.
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
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).
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
the si de of the ci rcui t cl osest to the battery (Fi g. 10).
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
(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.
part of the exposed wi re (exampl e 1). (Fi g. 11)
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)
(8) Center the heat shri nk tubi ng over the joi nt,
(9) Secure the wi re to the exi sti ng ones to prevent
chafi ng or damage to the i nsul ati on
CONNECTORS
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
(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
component.
(3) Push i n the two l ock tabs on the si de of the
(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 REPLACEMENT
(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
(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
(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.
CONNECTOR AND TERMINAL REPLACEMENT
(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.
si de of the wi re. Be sure the tubi ng wi l l be l ong
ends of the tubi ng
(14) Repeat steps 8 through 13 for each wi re.
(16) Re-connect the repai red connector.
(17) Connect the battery, and test al l affected sys-
tems.
TERMINAL REPLACEMENT
(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. 20 Stagger Cutting Wires
(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
(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.
(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.
(18) Connect battery, and test al l affected systems.
DIODE REPLACEMENT
(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. 24 Diode Identification
(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.
(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
INDEX
page
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
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
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
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
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.
INDEX
page
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 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
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
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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(+)
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(+)
*
J978W-3 ZGR01019
FUSED B(+)
X2 16DG/YL
A1
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
A6
F92 18LG
FUSED B(+)
ABS WARNING LAMP RELAY OUTPUT F250 18RD/GY
B1
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
ZGR01020 J978W-3
AUTOMATIC
SHUT DOWN
RELAY
B17
B16
F5 16RD/YL * FUSED IGNITION SWITCH OUTPUT (ST/RUN)
F5 16RD/YL *
B16
B16
F5 18RD/YL FUSED B(+)
FUSED B(+)
FUSED B(+)
WIPER PARK SWITCH SENSE V6 16DB
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
FUSED B(+)
FUSED B(+)
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
J978W-3 ZGR01021
- -
C9
C8
T141 14YL/RD FUSED IGNITION SWITCH OUTPUT (ST)
T40 12LG/BK
C7
C6
A1 12RD/WT FUSED B(+)
FUSED B(+) A61 16DG/BK
C16
A64 16DG/WT
F99 200R
C17
C18
-
RELAY
PUMP
FUEL
Z4 20BK
C10
C20
C19
K81 18DB
-
ENGINE
STARTER
MOTOR
RELAY
C10
T41 20BK/WT
*
**
FUEL HEATER FEED
A64 14OR/DB
D13
D14
FUEL
HEATER
RELAY
F99 20OR
D12
D11
-
Z4 20BK
D10
A12 12RD/TN FUSED B(+)
GROUND
(DIESEL)
-
* GAS
** DIESEL
ZGR01022 J978W-3
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
INDEX
page
Component Page
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 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
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 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
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
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 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 Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Ri ght Front Park Lamp . . . . . . . . . . . . . . . . 8W-12-15
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
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
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
J978W-3 ZGR01213
C13
4
L90
18
DB/RD
(OPTIONAL)
MODULE
OUTAGE
LAMP
3 4 5
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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
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
30
F61 16WT/OR
FUSED B(+) INTERNAL
30
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
J978W-3 ZGR01225
C15 BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
87
86
C14 WT/RD
85
30
FUSED B(+)
GROUND
FUNCTION CIRCUIT
-
87A
-
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(+)
ELECTRONIC
FLASHER
(I)
ZGR01226 J978W-3
30 M2 YL
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
FUSED B(+)
F62 RD 30
30 366 PK/OR
PARK LAMP FEED
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
85 714 BK/OR AUTO HEADLAMP RELAY CONTROL
J978W-3 ZGR01227
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.
INDEX
page
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
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
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
J978W-3 ZGR01514
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.
INDEX
page
Component Page
Automati c Shut Down Rel ay . . . . . . . . 8W-20-2, 4, 5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
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
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
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)
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)
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
CHARGING SYSTEM
A0 connects the battery to the PDC. Ci rcui t Z0 pro-
vi des ground for the generator.
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
cui t K900. Ci rcui t K900 connects to cavi ty C3 of the
PCM.
i nsi de the rel ay cl ose and connect ci rcui t F5 from the
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 ..
erator fi el d on ci rcui t K20. Ci rcui t K20 connects to
PCM cavi ty B10.
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)
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
the contacts i n the Automati c Shut Down (ASD) rel ay
are CLOSED.
erator fi el d on ci rcui t K20.
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
INDEX
page
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . 8W-21-3
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
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-3
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 4
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)
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)
GAS ENGINES
ZG-RHD
J978W-3 ZGR02103
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 cl utch pedal posi ti on swi tch for proper
operati on
Check the case ground of the engi ne starter
motor
INDEX
page
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 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 7 Gas Engi nes . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Fuse 16 Di esel Engi ne . . . . . . . . . . . . . . . . . . . . . . 8W-30-22
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
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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)
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
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
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)
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)
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)
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
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)
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)
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)
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)
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)
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)
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)
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)
DIESEL ENGINE
ZG-RHD
J978W-3 ZGR03031
INDEX
page page
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AUTOMATIC SHUT DOWN (ASD) RELAY . . . . . 34
AUTOMATIC SHUT DOWN RELAY (DIESEL) . . . 34
BATTERY FEED (DIESEL) . . . . . . . . . . . . . . . . . 33
BATTERY FEED . . . . . . . . . . . . . . . . . . . . . . . . 33
CCD BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CRANKSHAFT POSITION SENSOR (DIESEL) . . 36
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . 34
DUTY CYCLE EVAP\PURGE SOLENOID . . . . . . 39
EGR SOLENOID (DIESEL) . . . . . . . . . . . . . . . . 39
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
VEHICLE SPEED SENSOR (DIESEL) . . . . . . . . 35
WATER IN FUEL SENSOR (DIESEL) . . . . . . . . . 38
IGNITION SWITCH
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.
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.
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
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
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
i nsi de the rel ay cl ose and connect ci rcui t F5 from
spl i ces to, fuel i njectors, i gni ti on coi l and the
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
Refer to the appropri ate secti on of the servi ce
manual or Di agnosti c Test Procedures manual
FUEL PUMP RELAY
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
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
FUEL PUMP MOTOR
rel ay powers the fuel pump modul e. Ci rcui t Z1 pro-
FUEL LEVEL SENSOR
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)
FUEL PUMP MOTOR
rel ay powers the fuel pump motor. Ci rcui t Z1 pro-
FUEL LEVEL SENSOR
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.
Ci rcui t K6 suppl i es 5 vol ts from the Powertrai n
an i nput si gnal to the PCM. The G7 ci rcui t connects
sensor si gnal (ci rcui t G7) through ci rcui t K4. Ci rcui t
HELPFUL INFORMATION
Fuel pump modul e
VEHICLE SPEED SENSOR (DIESEL)
Ci rcui t K7 suppl i es vol tage from the Powertrai n
an i nput si gnal to the PCM.
HEATED OXYGEN SENSORS
tacts cl ose, ci rcui t A142 suppl i es vol tage to the
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.
Fuel pump modul e
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.
vol ts to the crankshaft posi ti on sensor on ci rcui t K25.
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.
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
shaft posi ti on sensor, mani fol d absol ute pressure sen-
sor and throttl e posi ti on sensor.
Fuel pump modul e
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.
posi ti on sensor (ci rcui t K24) through ci rcui t K4.
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 -
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.
Fuel pump modul e
The engi ne cool ant temperature sensor provi des an
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
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
Fuel pump modul e
(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.
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.
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.
Ci rcui t K22 del i vers the TPS si gnal to the PCM.
The PCM provi des a ground for the throttl e posi -
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.
Fuel pump modul e
(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
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.
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
HELPFUL INFORMATION
Refer to Group 14 for MAP sensor operati on.
shaft posi ti on sensor, crankshaft posi ti on sensor and
throttl e posi ti on sensor.
Fuel pump modul e
MASS AIR FLOW SENSOR (DIESEL)
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-
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
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
Fuel pump modul e
OIL PRESSURE SENSOR
the Powertrai n Control Modul e on ci rcui t G6. Ci rcui t
G6 connects to cavi ty B23 of the PCM.
sor on ci rcui t K4. Ci rcui t K4 connects to cavi ty A4 of
the PCM.
OIL PRESSURE SENSOR (DIESEL)
the Powertrai n Control Modul e on ci rcui t G60.
sor on ci rcui t K4.
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
FUEL INJECTORS
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.
Ci rcui t K12 provi des ground for i njector number two.
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.
Ci rcui t K38 provi des ground for i njector number fi ve.
Ci rcui t K58 provi des ground for i njector number si x.
On the 5.2L engi ne, ci rcui t K17 provi des ground
for i njector number seven. The K17 ci rcui t connects
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
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
are CLOSED. Ground for the sol enoi d i s control l ed
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
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
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 .
FUEL QUANTITY ACTUATOR
Power for the fuel quanti ty Actuator i s suppl i ed on
are CLOSED. Ground for the Actuator i s control l ed
FUEL HEATER (DIESEL)
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
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
HELPFUL INFORMATION
i njectors, PCM, heated oxygen sensors, and genera-
tor.
IDLE AIR CONTROL (IAC) MOTOR
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.
DUTY CYCLE EVAP\PURGE SOLENOID
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
INDEX
page
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
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
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . 8W-31-4
Torque Converter Cl utch Sol enoi d . . . . . . . . 8W-31-2
Vari abl e Force Sol enoi d . . . . . . . . . . . . . . . . 8W-31-2
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
INDEX
page page
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
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.
ter (PDC) wi th ci rcui t A22. Ci rcui t A22 powers 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.
posi ti ons, i t connects ci rcui t A1 from fuse 8 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
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
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.
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.
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
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.
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
Fuel pump modul e
8W - 31 - 8 8W - 31 TRANSMISSION CONTROL SYSTEM ZG
INDEX
page
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
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
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)
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)
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
VEHICLE SPEED CONTROL
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.
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.
vol ts.
ci rcui t K95 at PCM cavi ty C32 has nomi nal val ue of
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.
vol ts.
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
PCM.
VEHICLE SPEED CONTROL (DIESEL)
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
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.
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.
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.
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.
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
PCM.
8W - 33 - 6 8W - 33 VEHICLE SPEED CONTROL ZG
INDEX
page
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
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
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
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
INDEX
page page
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . 5
G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 5
STOP LAMP SWITCH INPUT . . . . . . . . . . . . . . . 5
WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . 5
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.
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.
from the ri ght front wheel speed sensor.
from the l eft front wheel speed sensor.
from ri ght rear wheel speed sensor.
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
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
on ci rcui t 205.
HELPFUL INFORMATION
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.
INDEX
page
Component Page
Sensor/Vtss Led . . . . . . . . . . . . . . . . . . . 8W-39-3
Body Control Modul e . . . . . . . . . . 8W-39-2, 3, 4, 5, 6
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6
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
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . 8W-39-2, 3, 6
Component Page
Li ftgate Ajar Swi tch . . . . . . . . . . . . . . . . . . 8W-39-4
Li ftgl ass Ajar Swi tch . . . . . . . . . . . . . . . . . . 8W-39-4
Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
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
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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.
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
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.
INDEX
page
Component Page
ABS Warni ng Lamp . . . . . . . . . . . . . . . . . . 8W-40-5
Brake Warni ng Lamp . . . . . . . . . . . . . . . . . 8W-40-5
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
Hi gh Beam I ndi cator Lamp . . . . . . . . . . . . . 8W-40-5
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 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
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
Vol t Meter . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
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)
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)
J978W-3 ZGR04005
INDEX
page page
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
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-
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 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
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 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 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
on ci rcui t 205.
HELPFUL INFORMATION
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
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
INDEX
page
Component Page
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 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
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
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
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
(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
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
INDEX
page
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
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
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
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)
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)
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)
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)
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)
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)
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)
DIESEL ENGINE
8W - 42 - 13
ZGR04212 J978W-3
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C OPERATIONAUTOMATIC TEMPERATURE
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A/C OPERATIONMANUAL A/C . . . . . . . . . . . . 14
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AUTOMATIC TEMPERATURE CONTROL (ATC) . 15
BLEND AIR DOOR MOTOR ACTUATOR
MANUAL A/C-HEATER . . . . . . . . . . . . . . . . . . 15
BLEND DOOR MOTORAUTOMATIC
BLOWER MOTORAUTOMATIC
BLOWER MOTORMANUAL A/C-HEATER . . . . 14
IN-CAR TEMPERATURE SENSOR . . . . . . . . . . 15
MANUAL A/C-HEATER . . . . . . . . . . . . . . . . . . . 14
MODE DOOR MOTORAUTOMATIC
RECIRCULATION DOOR MOTORAUTOMATIC
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.
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
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.
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.
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.
passes through two resi stors i n the resi stor bl ock to
passes through one resi stor i n the resi stor bl ock to
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
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
bus.
rel ay, the contacts cl ose and connect ci rcui t F250
cl utch.
HELPFUL INFORMATION
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.
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
to ci rcui t A22. Ci rcui t A22 powers ci rcui t F71
connects to the ATC modul e and the reci rcul ati on
door motor.
F60 suppl i es power to the ATC modul e.
posi ti on, i t connects ci rcui t A1 from PDC fuse 8 to
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.
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.
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.
rel ay, the contacts cl ose and connects ci rcui t F250
cl utch.
HELPFUL INFORMATION
RECIRCULATION DOOR MOTOR AUTOMATIC
TEMPERATURE CONTROL
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
swi tch i n the mode door motor. The ATC modul e
recei ves the sensor si gnal from the mode door motor
the ATC modul e.
BLEND DOOR MOTOR AUTOMATIC
TEMPERATURE CONTROL
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
the ATC modul e.
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.
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
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.
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-43 AIRBAG SYSTEM
INDEX
page
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-43-2, 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
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
AIRBAG IMPACT SENSOR . . . . . . . . . . . . . . . . . 4
AIRBAG SQUIB (AIRBAG IGNITER) . . . . . . . . . . 4
AIRBAG WARNING LAMP . . . . . . . . . . . . . . . . . . 4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 4
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
Ci rcui t F20 connects to the ACM.
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.
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)
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.
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
INDEX
page
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
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
Juncti on Bl ock . . . 8W-44-2, 3, 4, 5, 6, 7, 8, 9, 10, 13
Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-13
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
Mercury Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
Overhead Consol e . . . . . . . . . . . . . . . . . . . . 8W-44-4
Component Page
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8
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
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)
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)
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)
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)
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)
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)
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)
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)
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)
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
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)
J978W-3 ZGR04413
INDEX
page page
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
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.
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.
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.
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.
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
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
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.
consol e l amps.
DAY/NIGHT MIRROR
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
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
INDEX
page
Component Page
Ash Lamp Recei ver . . . . . . . . . . . . . . . . . . 8W-45-10
Sensor/Vtss Led . . . . . . . . . . . . . . . . . . . 8W-45-4
Body Control Modul e . 8W-45-2, 3, 4, 5, 6, 7, 8, 9, 10
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7
Dayti me Runni ng Lamp Modul e . . . . . . . . . 8W-45-5
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
Hood Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
I ntermi ttent Wi per Swi tch . . . . . . . . . . . . . 8W-45-7
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-45-2, 3, 4, 5, 7
Component Page
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-45-4
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
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
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)
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)
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)
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)
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)
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)
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)
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)
ZGR04510 J978W-3
INDEX
page page
A/C SELECT SWITCH . . . . . . . . . . . . . . . . . . . . 12
AJAR CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LOW OIL PRESSURE WARNING CHIME . . . . . . 13
PARK LAMP SWITCH SENSE . . . . . . . . . . . . . . 13
SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . . . . 13
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
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)
Memory Seat Modul e
Passenger Door Modul e (PDM)
Vehi cl e I nformati on Center
Radi o
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.
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
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
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.
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.
INDEX
page
Component Page
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
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-46-2, 3, 4, 5, 6
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
Vehi cl e I nformati on Center . . . . . . . 8W-46-4, 5, 6, 7
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)
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)
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)
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)
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)
OVERHEAD CONSOLE
8W - 46 - 7
ZGR04606 J978W-3
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 8
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.
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.
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
pl i es vol tage to the GDM.
the GDM. Ci rcui ts Z1 and Z2 provi de ground for the
GDM.
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.
connects ci rcui t G28 from the GDM to ground on ci r-
pl ay, the GDM al so i l l umi nates the LOW di spl ay.
4WD posi ti on, i t connects ci rcui t T107 from the GDM
the 4WD di spl ay, the GDM al so i l l umi nates the
PART TI ME di spl ay.
posi ti on, i t connects ci rcui t T106 from the GDM to
4WD di spl ay, the GDM al so i l l umi nates the FULL
TI ME di spl ay.
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
pl i es vol tage to the VI C.
the VI C.
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.
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.
connects ci rcui t G28 from the VI C to ground on ci r-
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
4WD posi ti on, i t connects ci rcui t T107 from the VI C
the 4WD di spl ay, the VI C al so i l l umi nates the PART
TI ME di spl ay.
posi ti on, i t connects ci rcui t T106 from the VI C to
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-
Z1. The VI C di spl ays the Low Washer Fl ui d warni ng
LOW ENGINE COOLANT WARNING
When the engi ne cool ant l evel swi tch cl oses, i t con-
Z1. The VI C di spl ays the Low Cool ant Level warni ng
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.
8W-47 AUDIO SYSTEM
INDEX
page
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
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
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)
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
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
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
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
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)
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)
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
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
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
(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.
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-
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-
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.
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
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
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.
Center (PDC) feeds the rel ay swi tch through fuse 13
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.
INDEX
page
Component Page
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
Component Page
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
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
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
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.
INDEX
page
Component Page
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
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
OVERHEAD CONSOLE
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.
consol e l amps.
8W - 49 - 4 8W - 49 OVERHEAD CONSOLE ZG
INDEX
page
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
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
I nstrument Cl uster . . . . . . . . . . . . . . . . 8W-50-9, 10
Juncti on Bl ock . . . . . . . . . . . . 8W-50-2, 4, 6, 7, 8, 10
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8W-50-7, 8
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Component Page
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-50-3
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
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)
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)
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)
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)
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)
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)
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)
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)
ZGR05010 J978W-3
INDEX
page page
AUTO HEADLAMPS . . . . . . . . . . . . . . . . . . . . . 12
FOG LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HEADLAMP LEVELING . . . . . . . . . . . . . . . . . . . 12
HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 12
PARKING LAMPS . . . . . . . . . . . . . . . . . . . . . . . 12
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
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
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
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
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
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
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.
8W-51 REAR LIGHTING
INDEX
page
Component Page
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 Rear Fog Lamp . . . . . . . . . . . . . . . . . . 8W-51-7
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . 8W-51-3, 4
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-51-2
Component Page
Rear Fog Lamp Rel ay A . . . . . . . . . . . . . . . 8W-51-7
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
Trai l er Tow Stop Lamp Rel ay . . . . . . . . . . . 8W-51-3
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
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)
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)
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)
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)
ZGR05106 J978W-3
8W-51 REAR LIGHTING
TAIL LAMPS, REAR LICENSE PLATE LAMPS AND
SIDE MARKER LAMPS
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
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
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
(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
Component Page
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
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-52-2, 4, 6, 7
Left Front Si de Marker Lamp . . . . . . . . . . . 8W-52-3
Left Front Turn Si gnal . . . . . . . . . . . . . . . . 8W-52-8
Left Park Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-52-8
Left Rear Turn Si gnal Lamp . . . . . . . . . . 8W-52-5, 7
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-52-8
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
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
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)
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)
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)
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)
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
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.
Center (PDC) powers the el ectroni c fl asher through
fuse 13 i n the juncti on bl ock.
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.
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.
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.
8W-53 WIPERS
INDEX
page
Component Page
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 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
Wi ndshi el d Washer Pump Motor . . . . . . . . . 8W-53-2
Wi ndshi el d Wi per Motor . . . . . . . . . . . . . 8W-53-2, 3
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
INTERMITTENT WIPER OPERATION
swi tch connects ci rcui t A1 from fuse 8 i n the PDC to
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-
Ci rcui t V3 powers the wi per motor l ow speed brush.
When the operator sel ects HI GH speed wi per oper-
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.
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.
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
Component Page
Aftermarket Trai l er Tow Connector . . . . . 8W-54-4, 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
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . 8W-54-2, 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
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 Stop Lamp Rel ay . . . . . . . . . 8W-54-2, 3
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.
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.
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
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
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,
L60.
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,
L61.
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
Component Page
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
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
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
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 5
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . 5
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
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.
The DDM connects ci rcui t Q11 to ci rcui t F81 and
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
The PDM connects ci rcui t Q12 to ci rcui t F81 and
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
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
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.
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.
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.
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.
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.
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.
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.
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
INDEX
page
Component Page
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 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
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
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.
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.
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
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
Component Page
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . 8W-62-4
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
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
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.
to a saved posi ti ons. The memory feature al so can set
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
reveres. The DDM suppl i es power to ci rcui t F73 and
Duri ng LEFT adjustments, the DDM suppl i es
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
reveres. The PDM suppl i es power to ci rcui t F73 and
Duri ng LEFT adjustments, the PDM suppl i es
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
Component Page
Ci rcui t Breaker 3 . . . . 8W-63-2, 3, 4, 8, 9, 10, 13, 14
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
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
Component Page
Passenger Lumbar Motor . . . . . . . . . . . . . . 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)
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)
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)
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)
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)
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)
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)
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)
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)
MEMORY SEAT
8W - 63 - 15
ZGR06314 J978W-3
8W-63 POWER SEAT
INDEX
page page
HEATED SEATS . . . . . . . . . . . . . . . . . . . . . . . . 17
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 16
MEMORY SEATS . . . . . . . . . . . . . . . . . . . . . . . 17
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . 16
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.
to saved posi ti ons. The memory feature al so can set
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
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
ground.
ground.
PASSENGERS SEAT
ground.
8W - 63 - 16 8W - 63 POWER SEAT ZG
ground.
MEMORY SEATS
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
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
(PDC) powers ci rcui t F35 through the ci rcui t breaker.
ZG 8W - 63 POWER SEAT 8W - 63 - 17
connects ci rcui t A1 from fuse 8 i n the PDC to ci rcui t
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
8W-64 POWER SUNROOF
INDEX
page
Component Page
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
POWER SUNROOF . . . . . . . . . . . . . . . . . . . . . . 4
POWER SUNROOF
Ci rcui t A31 powers ci rcui t F86 through the ci rcui t
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
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
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
INDEX
page
Component Page
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 Sol enoi d . . . . . 8W-65-3
Steeri ng Wheel Speed Sensor . . . . . . . . . . . 8W-65-3
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
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 4
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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.
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.
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.
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
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)
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)
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)
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)
DIESEL ENGINE
8W - 70 - 9
ZGR07008 J978W-3
8W-80 CONNECTOR PIN-OUTS
INDEX
page
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
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
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
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
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
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 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
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
(wi th 4.0L Engi ne) . . . . . . . . . . . . . . . . . 8W-80-34
(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
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 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 ntake Ai r Temperature Sensor . . . . . . . . . 8W-80-42
Juncti on Bl ock - C1 . . . . . . . . . . . . . . . . . . 8W-80-42
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 I nstrument Panel Speaker . . . . . . . . . 8W-80-50
Left Park Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-51
Left Park turn Si gnal Marker . . . . . . . . . . 8W-80-51
Left Rear Door Lock Motor . . . . . . . . . . . . 8W-80-51
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 Tai l /Stop Lamp . . . . . . . . . . . . . . . . . 8W-80-53
Left Vi sor/Vani ty Mi rror . . . . . . . . . . . . . . 8W-80-53
Li ftgate Cyl i nder Lock Swi tch . . . . . . . . . . 8W-80-53
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 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 - 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/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 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 Power Wi ndow Motor . . . . . . . 8W-80-71
Ri ght Front Si de Marker Lamp . . . . . . . . . 8W-80-72
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . 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
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 Speed Control Servo . . . . . . . . . . . 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 - 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
-
-
GROUND
PANEL LAMP DRIVER
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
RIGHT TURN SIGNAL
FUSED B(+)
CAV
A
B
C
D
L50 18WT/TN
L90 18DB/RD
L60 18TN
F70 18PK/BK
CIRCUIT FUNCTION
GROUND
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 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
CAV
C3 18DB/BK*
C13 16DB**
C21 18DB/OR
A/C LOW PRESSURE
SWITCH
BLACK
2 1
1
1
2
* GAS
** DIESEL
J978W-3 ZGR08006
BLACK
CIRCUIT
-
-
-
-
-
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
-
-
-
-
-
GROUND
FUSED IGNITION SWITCH OUTPUT (RUN/START)
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
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
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
CAV
1
2
D41 20LG/WT
C8 20DG/RD
AMBIENT
TEMPERATURE SENSOR
BLACK
2 1
CIRCUIT FUNCTION
FUSED B(+)
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
J978W-3 ZGR08007
CIRCUIT
-
-
-
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
-
-
-
A/C SELECT INPUT
5 VOLT SUPPLY
CCD BUS(+)
CCD BUS(-)
FUSED B(+)
HIGH SPEED BLOWER MOTOR RELAY CONTROL
GROUND
SENSOR RETURN
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
SENSOR GROUND
CAV
1
2
T222 18RD/YL
K4 18BK/LB
BATTERY
TEMPERATURE SENSOR
BLACK
1 2
CIRCUIT FUNCTION
BACK-UP SWITCH OUTPUT
CAV
1
2
F83 18YL/DG
L10 18BR/LG
BACK-UP LAMP SWITCH
(DIESEL)
1 2
BLACK
J978W-3 ZGR08008
CIRCUIT
-
FUNCTION
-
5 VOLT SUPPLY
SENSOR RETURN
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
6 5 4 3 2 1
BLACK
CIRCUIT
-
-
FUNCTION
-
-
5 VOLT SUPPLY
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
GROUND
CAV
1
2
C42 12RD
Z4 12BK
CIRCUIT FUNCTION
CAV
1
2
3
4
C4 14TN
C6 14LB
C7 12BK
C5 14LG
BLOWER MOTOR
(WITH AUTOMATIC
NATURAL
2 1
BLOWER MOTOR
RESISTOR BLOCK
(WITH MANUAL A/C-HEATER)
BLACK
2
3
1
4
J978W-3 ZGR08009

CIRCUIT
-
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
-
SENSOR RETURN
HOOD AJAR SWITCH SENSE
GROUND
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
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(+)
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
A/C SELECT INPUT
FUSED B(+)
ULTRALIGHT SENSOR SIGNAL
HORN RELAY CONTROL
PANEL LAMP DRIVER
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
J978W-3 ZGR08011

CIRCUIT FUNCTION
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
GROUND
RIGHT FRONT DOOR AJAR SWITCH SENSE
VTSS DISARM SENSE
LEFT REAR DOOR AJAR 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
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)
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
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
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
BLACK
BLACK
BLACK
BLACK
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
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
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
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
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
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
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
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
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
*
J978W-3 ZGR08026

CIRCUIT FUNCTION
5 VOLT SUPPLY
SENSOR GROUND
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
FUSED B(+)
CAV
A
B
C
M2 20YL
M1 20PK
M4 20WT/LG
BLACK
C A
CARGO LAMP
CIRCUIT FUNCTION
GROUND
GROUND
CAV
1
2
L87 20DG/WT
L87 20DG/WT
Z1 20BK
Z1 20BK
BLACK
NO. 1
1 2
CIRCUIT FUNCTION
GROUND
CAV
1
2
L87 20DG/WT
Z1 20BK
BLACK
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
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
GROUND
GROUND
CAV
1
2
L87 20DG/WT
L87 20DG/WT
Z1 20BK
Z1 20BK
BLACK
NO. 3
1 2
CIRCUIT FUNCTION
GROUND
CAV
1
2
F30 18RD/DB
Z1 18BK
CIGAR LIGHTER
BLACK
1
2

CIRCUIT
-
-
-
-
-
-
FUNCTION
-
-
-
-
-
-
LEFTT FRONT WHEEL SPEED SENSOR (+)
GROUND
SYSTEM RELAY
G SWITCH SENSOR GROUND
SCI RECEIVE
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
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
CAV
1
2
3
K4 20BK/LB
K24 20GY/BK
CIRCUIT FUNCTION
-
5 VOLT SUPPLY
SENSOR GROUND
CAV
1
2
3
K25 20WT/BK
K4 20BK/LB
K27 18RD/LG
(DIESEL)
(GAS)
CIRCUIT FUNCTION
ENGINE COOLANT LEVEL SENSE
GROUND
CAV
1
2
G18 16PK/BK
Z1 16BK
1
BLACK
2
1
BLACK
2 3
1
BLACK
2
3
J978W-3 ZGR08029

CIRCUIT FUNCTION
GROUND
FUSED B(+)
CAV
A
B
C
Z1 20BK
M2 2OYL
M1 20PK
DOME/READING
LAMP
NATURAL
A C
CIRCUIT FUNCTION
GROUND
CCD BUS (+)
CCD BUS (-)
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
GROUND
SENSOR GROUND
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
SENSOR GROUND
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
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
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
CAV
1
2
P106 18DG/WT
P107 18OR/BK
BLACK
DRIVER LUMBAR
MOTOR
2 1
J978W-3 ZGR08031

CIRCUIT FUNCTION
SENSOR GROUND
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
CAV
1
1
2
2
P115 16GY/LG*
P15 16YL/LB
P117 16RD/BR*
P17 16RD/LB
CIRCUIT FUNCTION
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
CAV
1
2
P121 16RD/GY*
P21 16RD/LG
P119 16YL/RD*
P19 16YL/LG
CIRCUIT FUNCTION
SENSOR GROUND
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
J978W-3 ZGR08032
CIRCUIT FUNCTION
GROUND
FUSED B(+)
GROUND 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
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
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
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
J978W-3 ZGR08033

CIRCUIT FUNCTION
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 DRIVER
FUSED B(+)
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 B(+)
HEATED SEAT DRIVER
GROUND
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
J978W-3 ZGR08034
2 1
DRIVER SIDE
AIRBAG
YELLOW
CIRCUIT FUNCTION
CAV
1
2
R45 18DG/LB
R43 18BK/LB
CIRCUIT FUNCTION
CAV
1
2
F99 20OR
K52 18PK/BK
1
DUTY CYCLE
EVAP/PURGE SOLENOID
BLACK
2
CIRCUIT FUNCTION
EXHAUST GAS RCIRCULATION SOLENOID
GROUND
CAV
1
2
4
A142 16DG/OR
K35 16GY/YL
Z1 18BK
EGR SOLENOID
(DIESEL)
CIRCUIT FUNCTION
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
SENSOR GROUND
CAV
1
2
K2 16TN/BK
K4 16BK/LB
ENGINE COOLANT
TEMPERATURE SENSOR
(WITH 4.OL ENG)
CIRCUIT FUNCTION
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
J978W-3 ZGR08035
* GAS
** DIESEL
CIRCUIT FUNCTION
B(+)
B(+)
CAV
1
1
2
2
A0 6RD
A0 2RD**
T40 12LG/BK
T40 14LG/BK**
ENGINE STARTER MOTOR
BLACK
1
2
CIRCUIT
-
FUNCTION
-
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
FUSED B(+)
LEFT TURN SIGNAL
RIGHT TURN SIGNAL
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
J978W-3 ZGR08036
CIRCUIT FUNCTION
SLEEVE POSITION SENSOR (-)
CONT SLEEVE POSITION SENSOR
SENSOR GROUND
SHUTOFF FEED
FUEL TEMP SENSOR SIGNAL
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
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
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
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
J978W-3 ZGR08037

CIRCUIT FUNCTION
G SWITCH GROUND
CAV
1
2
3
B43 20PK/OR
B41 20YL/VT
B42 20TN/WT
G-SWITCH
CIRCUIT
-
FUNCTION
-
CAV
1
2
3
A142 16DG/OR
K20 18DG/YL
GENERATOR
(DIESEL)
CIRCUIT
-
FUNCTION
-
GROUND
CAV
1
2
3
4
Z0 8BK
K72 18DG/VT
K20 18DG
GENERATOR
(GAS)
CIRCUIT FUNCTION
BATTERY POSITIVE
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
J978W-3 ZGR08038
CIRCUIT
-
-
-
FUNCTION
-
-
-
FUSED B(+)
GROUND
TURN SIGNAL
CCD BUS (+)
CCD BUS (-)
PANEL LAMP DRIVER
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
J978W-3 ZGR08039
CIRCUIT
-
-
-
FUNCTION
-
-
-
PANEL LAMP DRIVER
GROUND
GROUND
COIL DRIVER #6
FUSED B(+)
PARK LAMP FEED
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
J978W-3 ZGR08040
CIRCUIT FUNCTION
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
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
CAV
1
2
K19 18GY/WT
A142 18DG/OR
IGNITION COIL
1
BLACK
2
CIRCUIT FUNCTION
IGNITION SWITCH OUTPUT (START)
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
SENSOR GROUND
CAV
A
B
C10 20RD/TN
D41 20LG/WT
IN-CAR TEMPERATURE
SENSOR
BLACK
B
J978W-3 ZGR08041

CIRCUIT FUNCTION
INJECTOR NO.1 DRIVER
CAV
1
2
A142 18DG/OR
K11 18WT/DB
CIRCUIT FUNCTION
CAV
1
2
A142 18DG/OR
K12 18TN
GRAY
2
FUEL INJECTOR
NO.1
1
GRAY
2
FUEL INJECTOR
NO.2
1
CIRCUIT FUNCTION
CAV
1
2
A142 18DG/OR
K13 18YL/WT
GRAY
2
FUEL INJECTOR
NO.3
1
CIRCUIT FUNCTION
CAV
1
2
A142 18DG/OR
K14 18LB/BR
GRAY
2
FUEL INJECTOR
NO.4
1
CIRCUIT FUNCTION
CAV
1
2
A142 18DG/OR
K38 18GY
GRAY
2
FUEL INJECTOR
NO.5
1
J978W-3 ZGR08042
CIRCUIT FUNCTION
CAV
1
2
A142 18DG/OR
K58 18BR/YL
GRAY
2
FUEL INJECTOR
NO.6
1
CIRCUIT FUNCTION
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(+)
FUSED B(+)
FUSED B(+)
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
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(+)
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
SENSOR GROUND
CAV
1
2
K21 16BK/RD
K4 16BK/LB
GRAY
INTAKE AIR
TEMPERATURE SENSOR
1 2
J978W-3 ZGR08043

JUNCTION BLOCK - C3
CIRCUIT
-
-
-
-
FUNCTION
-
-
-
-
HORN RELAY CONTROL
2-WHEEL DRIVE LAMP/LOW RANGE
FUSED B(+)
FUSED B(+)
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
-
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
AUTO HEADLAMP RELAY OUTPUT
FUSED B(+)
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
FUSED B(+)
FUSED B(+)
FUSED B(+)
CAV
1
2
3
4
A21 12DB/GY
A7 12YL/RD
A900 12OR/YL
A250 10RD
J978W-3 ZGR08044
JUNCTION BLOCK - C6
3
1
4
2
BLACK
CIRCUIT FUNCTION
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
-
-
FLASH TO PASS
HAZARD SIGNAL
REAR FOG LAMP
GROUND
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 B(+)
FUSED B(+)
FUSED B(+)
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
J978W-3 ZGR08045

8
3
1
12
7
2
JUNCTION BLOCK - C9
LIGHT
GRAY
CIRCUIT
-
-
-
FUNCTION
-
-
-
REAR WINDOW DEFOGGER LAMP DRIVER
FUSED B(+)
FUSED B(+)
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
GREEN
CIRCUIT
-
-
FUNCTION
-
-
FUSED B(+)
HORN 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
CAV
1
2
3
X17 20DG
X14 20WT
X16 20GY
BLACK
1
3
2
* AUTOMATIC TEMP CONTROL
2
7
12
3
8
1
JUNCTION BLOCK
NATURAL
CIRCUIT
-
-
-
-
-
FUNCTION
-
-
-
-
-
FUSED B(+)
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
J978W-3 ZGR08046
BLACK
1
3 6
7 10
2
JUNCTION BLOCK
CIRCUIT
-
-
FUNCTION
-
-
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 B(+)
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
(OVERHEAD CONSOLE)
BLACK
CIRCUIT FUNCTION
GROUND
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
J978W-3 ZGR08047

CIRCUIT
-
FUNCTION
-
NOT USED
NOT USED
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
CIRCUIT FUNCTION
NOT USED
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
CAV
1
2
R47 18DB/LB
R49 18LB
LEFT AIRBAG
SENSOR
BLACK
1 2
J978W-3 ZGR08048
CIRCUIT FUNCTION
GROUND
CAV
A
G
L10 18BR/LG
Z1 18BK
BLACK
LEFT BACK-UP LAMP
A
G
CIRCUIT FUNCTION
FUSED B(+)
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
J978W-3 ZGR08049

CIRCUIT FUNCTION
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
CAV
1
2
Q11 16LB
Q21 16WT
BLACK
LEFT FRONT POWER
WINDOW MOTOR
2 1
CIRCUIT FUNCTION
GROUND
CAV
A
B
L90 18DB/RD
Z1 18BK
WHITE
LEFT FRONT PARK LAMP
B A
CIRCUIT FUNCTION
CAV
A
B
L90 18DB/RD
L64 18TN/DB
GRAY
LEFT FRONT SIDE MARKER LAMP
B A
J978W-3 ZGR08050
BLACK
LEFT FRONT TURN
SIGNAL LAMP
A
G
CIRCUIT FUNCTION
GROUND
CAV
A
G
L64 18TN/DB
Z1 18BK
CIRCUIT FUNCTION
LEFT FRONT WHEEL SPEED SENSOR (-)
CAV
1
2
B8 20RD/DB
B9 20RD
LEFT FRONT
WHEEL SPEED SENSOR
BLACK
2 1
CIRCUIT FUNCTION
GROUND
CAV
1
2
3
Z1 16BK
L4 16VT/OR
L3 16RD/OR
LEFT HEADLAMP
BLACK
1
2
3
CIRCUIT FUNCTION
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
J978W-3 ZGR08051

CIRCUIT FUNCTION
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
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
J978W-3 ZGR08052
CIRCUIT FUNCTION
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
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
GROUND
CAV
A
G
L60 18TN
Z1 18BK
BLACK
LEFT REAR TURN
SIGNAL LAMP
A
G
CIRCUIT FUNCTION
CAV
A
B
B3 20LG/DB
B4 20LG
LEFT REAR WHEEL
SPEED SENSOR
B A
BLACK
CIRCUIT FUNCTION
CAV
1
2
Q12 16BR
Q22 16VT
2
LEFT REAR POWER
WINDOW MOTOR
BLACK
1
1
2
J978W-3 ZGR08053

CIRCUIT FUNCTION
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
CAV
1
2
3
Z1 20BK
G78 20TN/BK
1
BLACK
3
CIRCUIT FUNCTION
VTSS DISARM SENSE
GROUND
CAV
1
2
G71 20VT/YL
Z1 20BK
1
LIFTGATE
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
J978W-3 ZGR08054
CIRCUIT
-
FUNCTION
-
GROUND
LIFTGLASS AJAR SWITCH SENSE
CAV
1
2
3
Z1 20BK
G78 20TN/BK
1
BLACK
3
CIRCUIT FUNCTION
FUSED B(+)
CAV
A
B
F70 16PK/BK
P101 16OR/PK
A
LIFTGLASS LIMIT SWITCH
NATURAL
B
CIRCUIT FUNCTION
CAV
1
2
P100 14OR/BR
P101 16OR/PK
1
LIFTGLASS PUSH BUTTON
BLACK
2
CIRCUIT FUNCTION
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
J978W-3 ZGR08055

CIRCUIT FUNCTION
GROUND
SENSOR GROUND
FUSED (B+)
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
CONT SLEEVE POS SENSE
NEEDLE MOVE SENSOR (-)
NEEDLE MOVE SENSOR (+)
ENGINE COOLANT TEMPERATUR SENSOR SIGNAL
POWER GROUND
EGR SOLENOID CONTROL
FLT SIGNAL
COIL DRIVER #2
SLEEVE POSITION SENSE
SENSOR GROUND
VEHICLE SPEED CONTROL SWITCH SIGNAL
A/C SWITCH SIGNAL
FUEL HEATER RELAY OUTPUT
AUTOMATIC SHUTDOWN RELAY CONTROL
AUTO SHUT DOWN RELAY (+)
POWER GROUND
FUEL TIMING SHUTOFF SENSOR
SHUTOFF FEED
5 VOLT SUPPLY
SCI RECEIVE
FUEL TEMPERATURE SENSOR SIGNAL
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
8W - 80 -56 ZG-RHD 8W-80 CONNECTOR PIN-OUTS
J978W-3 ZGR08056
CIRCUIT
-
FUNCTION
-
SENSOR GROUND
RECLINER POSITION 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
GROUND
FUSED B(+)
FUSED B(+)
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
J978W-3 ZGR08057

CIRCUIT FUNCTION
GROUND
CCD BUS(+)
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
5 VOLT SUPPLY
SENSOR RETURN
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
-
-
-
-
-
HAZARD SIGNAL
TURN SIGNAL
TURN SIGNAL
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
J978W-3 ZGR08058
CIRCUIT FUNCTION
SENSOR GROUND
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
CAV
1
2
T14 18LG/WT
T13 18DB/BK
OUTPUT SHAFT
SPEED SENSOR
BLACK
1 2
CIRCUIT FUNCTION
GROUND
CCD BUS(+)
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
J978W-3 ZGR08059

CIRCUIT FUNCTION
PARK/NEUTRAL POSITION SWITCH SENSE
CAV
1
2
3
L10 18BR/LG
T41 20BK/WT
F83 18YL/DG
BLACK
PARK/NEUTRAL POSITION
SWITCH
1 3
CIRCUIT FUNCTION
CAV
A
B
R44 18DB
R42 18VT
B A
PASSENGER
AIRBAG
YELLOW
CIRCUIT FUNCTION
RIGHT FRONT DOOR UNLOCK DRIVER
RIGHT FRONT DOOR LOCK DRIVER
GROUND
CCD BUS(+)
CCD BUS(-)
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
SENSOR GROUND
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
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
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
CAV
1
2
P106 18DG/WT
P107 18OR/BK
BLACK
PASSENGER
LUMBAR MOTOR
1 2
CIRCUIT FUNCTION
GROUND
FUSE B(+)
GROUND
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
J978W-3 ZGR08061

CIRCUIT FUNCTION
CAV
1
2
P20 16RD/LG
P18 16YL/LG
RED
FRONT RISER MOTOR
1 2
CIRCUIT FUNCTION
CAV
1
2
P14 16YL/LB
P16 16RD/LB
BLACK
HORIZONTAL MOTOR
1 2
CIRCUIT FUNCTION
CAV
1
2
P12 16RD/WT
P10 16YL/WT
RED
REAR RISER MOTOR
1 2
CIRCUIT FUNCTION
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
FUSED B(+)
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
J978W-3 ZGR08062
PASSENGER SEAT HEATER
CONTROL MODULE
CIRCUIT
-
-
-
FUNCTION
-
-
-
FUSED B(+)
HEATED SEAT DRIVER
GROUND
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 REAR (+)
RIGHT FRONT (+)
RIGHT REAR (-)
RIGHT REAR (+)
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(+)
LEFT REAR (+)
LEFT FRONT (+)
AMPLIFIED LEFT REAR (-)
FUSED B(+)
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
WHITE
1
WHITE
10
1
5
7
6
14
CIRCUIT FUNCTION
5 VOLT SUPPLY
SENSOR GROUND
CAV
3
5
7
8
10
K255 20WT/DG
K151 20WT
K6 20VT/WT
K4A 18BK/LB
K22 20OR/DB
(DIESEL)
1 6
5 10
J978W-3 ZGR08063

CIRCUIT
-
-
-
-
-
FUNCTION
-
-
-
-
RADIO GROUND
RIGHT FRONT SPEAKER(-)
LEFT FRONT SPEAKER (-)
LEFT REAR SPEAKER(-)
LEFT REAR SPEAKER (+)
RIGHT REAR SPEAKER (+)
LEFT FRONT SPEAKER (+)
RIGHT FRONT SPEAKER(+)
RADIO GROUND
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(+)
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
J978W-3 ZGR08064
CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
1
2
F38 18OR
Z1 18BK
POWER OUTLET
BLACK
2
1
SENSOR GROUND
5 VOLT SUPPLY
FUSED B(+)
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
J978W-3 ZGR08065

TORQUE CONVERTER CLUTCH SOLENOID CONTROL
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
J978W-3 ZGR08066
VOLTAGE REGULATOR SIGNAL
LOW FUEL SENSE
SCI RECEIVE
CCD BUS (-)
SCI TRANSMIT
CCD BUS (+)
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
J978W-3 ZGR08067

LOW FUEL WARNING
FUSED B(+)
SENSOR GROUND
5 VOLT SUPPLY
GROUND
GROUND
WATER-IN-FUEL SENSE
DISTRIBUTOR PICK-UP SIGNAL
SCI RECEIVE
CCD BUS(+)
WAIT TO START LAMP
SCI TRANSMIT
CCD BUS(-)
ENGINE COOLANT LEVEL SIGNAL
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)
BLACK
41 21 1
60 40 20
J978W-3 ZGR08068
CIRCUIT
-
FUNCTION
-
LEFT FRONT (-)
RIGHT FRONT (-)
PANEL LAMP DRIVER
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
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
J978W-3 ZGR08069

REAR WASHER
PUMP MOTOR
BLACK
CIRCUIT FUNCTION
GROUND
CAV
1
2
V20 18WT/BK
Z2 18BK
1
2
CIRCUIT FUNCTION
FUSED (B+)
GROUND
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
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
-
-
CAV
1
2
3
4
5
C33 20VT/OR
C32 20LB/DG
F71 20PK/DG
RECIRCULATION DOOR
ACTUATOR
(WITH AUTOMATIC
YELLOW
1 2 3 4 5
J978W-3 ZGR08070
CIRCUIT FUNCTION
CAV
1
2
R46 18BR/LB
R48 18TN
RIGHT AIRBAG
SENSOR
BLACK
2 1
CIRCUIT FUNCTION
GROUND
CAV
A
G
L10 18BR/LG
Z1 18BK
BLACK
RIGHT BACK-UP LAMP
A
G
CIRCUIT FUNCTION
FUSED B(+)
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
CAV
1
2
Z1 18BK
L39 18LB
RIGHT FOG LAMP
1 2
BLACK
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
GROUND
CAV
A
B
L90 18DB/RD
Z1 18BK
WHITE
RIGHT FRONT PARK LAMP
B A
CIRCUIT FUNCTION
CAV
1
2
Q12 16BR
Q22 16VT
BLACK
RIGHT FRONT POWER
WINDOW MOTOR
2 1
J978W-3 ZGR08073

CIRCUIT FUNCTION
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
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
GROUND
CAV
1
2
3
L64 18TN/DB
L90 18DB/RD
Z1 18BK
RIGHT PARK TURN
SIGNAL MARKER
2 1
3
BLACK
J978W-3 ZGR08074
CIRCUIT FUNCTION
GROUND
CAV
1
2
Z1 18BK
L22 18LB
NATURAL
RIGHT REAR SIDE
MARKER LAMP
1 2
CIRCUIT FUNCTION
GROUND
CAV
A
G
L61 18LG
Z1 18BK
BLACK
RIGHT REAR TURN
SIGNAL LAMP
A
G
FUNCTION CIRCUIT
CAV
A
B
B1 20YL/DB
B2 20YL
RIGHT REAR WHEEL
SPEED SENSOR
A B
RED
CIRCUIT FUNCTION
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
CAV
1
2
Q12 16BR
Q22 16VT
2
RIGHT REAR POWER
WINDOW MOTOR
BLACK
1
J978W-3 ZGR08075

CIRCUIT FUNCTION
FUSED B(+)
GROUND
CAV
A
B
M1 20PK
Z1 20BK
A
RIGHT VISOR/
VANITY MIRROR
BLACK
B
CIRCUIT FUNCTION
GROUND
CAV
1
2
G10 20LG/RD
Z1 20BK
SEAT BELT
SWITCH
CIRCUIT FUNCTION
SHIFT INTERLOCK SOLENOID SENSE
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
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
J978W-3 ZGR08076
SPEED PROPORTIONAL
STEERING MODULE
GREEN
CIRCUIT
-
-
-
FUNCTION
-
-
-
LOW
HIGH
5 VOLT SUPPLY
GROUND
SCI TRANSMIT
SCI RECEIVE
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
J978W-3 ZGR08077

STEERING WHEEL
SPEED SENSOR
CIRCUIT FUNCTION
5 VOLT SUPPLY
CAV
A
B
C
D
S1 20BK/YL
S2 20BK/LG
S3 20PK/WT
S4 20VT
A D
NATURAL
CIRCUIT
-
FUNCTION
-
GROUND
PANEL LAMP DRIVER
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
CAV
1
2
3
4
Z1 16BK
Q41 18WT
Q42 18LB
F86 18LG/BK
SUNROOF CONTROL
MODULE
CIRCUIT FUNCTION
GROUND
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
J978W-3 ZGR08078

CIRCUIT FUNCTION
5 VOLT SUPPLY
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

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
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
J978W-3 ZGR08079

CIRCUIT FUNCTION
GROUND
FUSED B(+)
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
TORQUE CONVERTER CLUTCH SOLENOID OUTPUT
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
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
J978W-3 ZGR08080
CIRCUIT FUNCTION
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
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
-
-
-
FUSED B(+)
GROUND
TURN SIGNAL
CCD BUS (+)
CCD BUS (-)
PANEL LAMP DRIVER
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
CAV
1
2
3
K6 18VT/WT
K4 18BK/LB
G7 18WT/OR
1 3
(GAS)
BLACK
J978W-3 ZGR08081

CIRCUIT FUNCTION
GROUND
CAV
A
B
V11 18TN/BK
Z2 18BK
CIRCUIT
-
FUNCTION
-
GROUND
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
GROUND
CAV
A
B
G29 16BK/TN
Z2 16BK
WIPER
FLUID LEVEL
SENSOR
BLACK
B A
CIRCUIT FUNCTION
8 VOLT SUPPLY
SENSOR GROUND
CAV
1
2
3
K7 20OR
K167 20BR/YL
G7 20WT/OR
(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
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.
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
(Diesel Engine)
13
C142 BK Corner of Engine
Compartment At
PCM
N/S
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
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
Panel, In Connector
Bracket
N/S
C300 YL Lower Instrument
Panel
N/S
C301 NAT Lower Instrument
Panel, In Connector
Bracket
N/S
Panel, In Connector
Bracket
N/S
C304 GY Lower Instrument
Panel
N/S
Panel, In Connector
Bracket
N/S
Panel
N/S
C309 GY In Left Rear Door 21
C320 GY Right Rear Quarter
Panel, Near Bottom
of Liftgate Opening
18
C322 GN In Liftgate 23
C328 GY Left Rear Quarter
Panel, Near Bottom
of Liftgate Opening
19
Passenger Seat
19
Connector
Name/Number
Color Location Fig.
C330 GY In Right Rear Door 21
C334 BK In Left Front Door 20
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
C372 BK Right Rear Quarter
Panel
22
(Diesel)
11
C917 BK Near Generator N/S
Camshaft Position
Sensor
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
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
Driver Door
Module C3
Driver Heated
Seat Back
BK Under Drivers Seat N/S
Driver Heated
Seat Cushion
Driver Lumbar
Motor
Driver Power Seat
Front Riser Motor
RD Under Drivers Seat N/S
Driver Power Seat
Front Riser Motor
Sensor
Driver Power Seat
Horizontal Motor
Driver Power Seat
Horizontal Motor
Sensor
Driver Power Seat
Lumbar Motor
Sensor
Driver Power Seat
Lumbar Switch
Driver Power Seat
Rear Riser Motor
RD Under Drivers Seat N/S
Driver Power Seat
Rear Riser Motor
Sensor
Driver Power Seat
Recliner Motor
Driver Power Seat
Recliner Motor
Sensor
Driver Power Seat
Switch
GN Under Drivers Seat N/S
Driver Seat
Heater Control
Module
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
Block 4.0L Engine
Below Generator
5.2L Engine
8
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
Shield
2
Shield
2
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
of Seat
19
of Seat
19
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
Right Front of
Vehicle
1
Right Front of
Vehicle
1
Idle Air Control
Motor
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.
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
Junction Block -
C3
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
Junction Block -
C9
Junction Block -
C10
Junction Block
Body Connector -
C13
Junction Block
Body Connector -
C14
Key-In Switch/
Halo Lamp
GY On Steering
Column, Near
Ignition Switch
16
Lamp Outage
Module C1
Panel, Near Bottom
of Liftgate Opening
19
Connector
Name/Number
Color Location Fig.
Lamp Outage
Module C2
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
Left Front Door
Lock Motor
Left Front Door
Speaker
Left Front Park
Lamp
WT At Lamp N/S
Left Front Power
Window Motor
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
Left Rear Power
Window Motor
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
Memory Seat
Module
Connector C1
Memory Seat
Module
Connector C2
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
Output Shaft
Speed Sensor
BK Left Side of
Transmission
7, 10
Overhead
Console
RD Center of Headliner,
Above Rear View
Mirror
17
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
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
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
Right Front Door
Lock Motor
Right Front Door
Speaker
Right Front Park
Lamp
WT At Lamp N/S
Right Front Power
Window Motor
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
of Engine
Compartment
2
Right Headlamp BK Right Fog Lamp 1
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
Right Rear Power
Window Motor
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
Trailer Tow Circuit
Breaker
BK Right Rear Quarter
Panel
22
Trailer Tow Left
Turn Relay
Panel
22
Trailer Tow Right
Turn Relay
Panel
22
Trailer Tow Stop
Lamp Relay
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
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Fig. 25 License Plate Lamps
8W-95 SPLICE LOCATIONS
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
Sensor T/O
1
Sensor T/O
1
Compartment
1
Compartment
1
Compartment
1
Compartment
1
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
Servo T/O
1
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
Engine)
2
S128 Near T/Os for Injectors 6 and 8
(5.2L Engine)
3
Engine)
3
S129 Rear of Engine (Diesel Engine) N/S
S130 Near Crankshaft Position
Sensor T/O (5.2L Engine)
3
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
S133 In Branch to Oil Pressure
Sensor and Crankshaft Position
Sensor (4.0L Engine)
2
Engine)
3
S134 Near Branch to Powertrain
Control Module (4.0L Engine)
2
Splice
Number
Location Fig.
4
S135 Near Branch to PCM (4.0L
Engine)
2
S135 Right Rear of Engine (5.2L
Engine)
3
Engine)
3
4
4
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
Module/Vehicle Information
Center
5
Module/Vehicle Information
Center
5
Splice
Number
Location Fig.
S316 Near Right Side T/O for Liftgate 9
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
11
11
S328 In Liftgate, Near Rear Window
Defogger T/O
12
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
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
Near Riser Motor Sensor T/O
N/S
Between Riser Motor Sensor
T/O and Heated Seat Module
T/O
N/S
Near Seat Switch T/O
N/S
S404 In Right Power Seat Harness,
Near Seat Motor T/Os
N/S
Near Seat Motor T/Os
N/S
In Branch to Seat Switch
N/S
Splice
Number
Location Fig.
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,
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,
Grommet
N/S
S417 In Right Tail Lamp Harness,
Grommet
N/S
S418 In License Plate Lamp Harness 12
S419 In License Lamp Harness 12
S421 Fuse Link at PDC N/S
F
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.
1
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4
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3
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S
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5
.
2
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F
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Fig. 7 HVAC Harness Splices
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Fig. 10 Roof Wiring Splices
Fig. 11 Front Door Harness Splices
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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
(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.
beari ng; shi m No.1 and No.3 mai n beari ng.
5.2/5.9L ENGINE When checki ng No.5 mai n
4.0L ENGINE When checki ng No.5 mai n
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
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
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
(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
(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
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
(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
ENGINE DIAGNOSIS
INDEX
page page
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
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . 10
INSPECTION (ENGINE OIL LEAKS IN
GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . 8
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.
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
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.
(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
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
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:
(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
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
ENGINEPERFORMANCE
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
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.)
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).
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).
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).
4. Faulty coil. 4. Test and replace, as necessary (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.
9 - 12 ENGINE ZG
ENGINEMECHANICAL
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.
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.
4. Excessive bearing
clearance.
4. Measure bearings for correct clearance.
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
ENGINELUBRICATION
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.
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
4.0L ENGINE
INDEX
page page
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
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
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
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 48
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 46
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 50
ENGINE CYLINDER HEAD COVER . . . . . . . . . 49
SPECIFICATIONS
4.0L ENGINE SPECIFICATIONS . . . . . . . . . . . . 51
SPECIAL TOOLS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 54
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
Oil Lubrication System
OIL GALLERY CAMSHAFT BEARING NUMBER 1 CAMSHAFT BEARING JOURNAL CAMSHAFT SPROCKET
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
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)
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
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
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
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
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
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
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
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
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
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
(2) Support the engi ne.
(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
(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
(5) Remove the engi ne support.
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
(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
(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.
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
(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.
(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.
(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
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.
(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.
(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.
(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.
(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
(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.
(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
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
(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.
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
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.
(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.
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
REMOVAL
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.
(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
(a) Ti ghten al l bol ts i n sequence (1 through 14)
(b) Ti ghten al l bol ts i n sequence (1 through 14)
(c) Check al l bol ts to veri fy they are set to 61
(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).
(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.
(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
(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.
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
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.
VIBRATION DAMPER
REMOVAL
(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
(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).
Fig. 37 Hydraulic Valve Tappet Removal
InstallationTool
HYDRAULIC TAPPET REMOVAL TOOL
CYLINDER BLOCK
TIMING CASE COVER
REMOVAL
(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 .
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
(12) I nstal l the serpenti ne dri ve bel t and ti ghten
to obtai n the speci fi ed tensi on.
TIMING CHAIN AND SPROCKETS
REMOVAL
(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).
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
(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
(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.
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.
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.
(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.
(8) Remove the rocker arms, bri dges and pi vots.
(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.
(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
(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).
(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.
CAMSHAFT PIN REPLACEMENT
REMOVAL
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(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.
(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
(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
(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
(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
(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.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(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
(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
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
(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
(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
(15) I nstal l the spark pl ugs. Ti ghten the pl ugs to
(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 .
OIL PAN
REMOVAL
(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
(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
(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.
(17) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
(18) Start the engi ne and i nspect for l eaks.
PISTONS AND CONNECTING RODS
REMOVAL
(2) Remove the rocker arms, bri dges and pi vots.
(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.
(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
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).
(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
(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.
(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)
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 .
(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
(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
(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 .
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.
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.
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
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
(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.
(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
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
(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
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.
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.
(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
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.)
No. 3 . . . . . . . . . . . . . . . . . . 32.28 to 32.33 mm
(1.271 to 1.273 i n.)
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.)
Taper (Max.) . . . . . . . . . . . 0.025 mm (0.001 i n.)
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.)
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)
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 )
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.)
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
5.2L ENGINE
INDEX
page page
GENERAL INFORMATION
PISTON AND CONNECTING ROD ASSEMBLY . 56
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . 60
SERVICE PROCEDURES
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 62
FITTING PISTON RINGS . . . . . . . . . . . . . . . . . 61
FITTING PISTONS . . . . . . . . . . . . . . . . . . . . . . 61
MEASURING TIMING CHAIN STRETCH . . . . . . 60
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 60
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . 71
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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
FRONT CRANKSHAFT OIL SEAL . . . . . . . . . . . 76
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . . 68
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . 70
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE . . . . . . . . . . . . 66
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 81
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 79
CRANKSHAFT JOURNALS . . . . . . . . . . . . . . . 82
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . 84
CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . 82
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SPECIFICATIONS
5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SPECIAL TOOLS
5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 85
GENERAL INFORMATION
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
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.
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.
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 .)
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.)
Crankshaft . . . . . . . . . . . . . . . . . . . . . Nodul ar 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
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.
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.
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.
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
F
i
g
.
3
O
i
l
L
u
b
r
i
c
a
t
i
o
n
S
y
s
t
e
m
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
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.)
(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
(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.)
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.
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.
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
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.
ENGINE MOUNTSFRONT
REMOVAL
(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.
(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
SILL BRACKET ASSEMBLY ENGINE SUP- PORT INSULA- TOR ASM. THROUGH-BOLT RIGHT SIDE
ENGINE SUPPORT INSULATOR ASM. TOP BOLTS BOTTOM BOLTS SIDE BOLTS SILL BRACKET ASSEMBLY THROUGH-BOLT LEFT SIDE
(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-
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
(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.
(6) Remove l i fti ng fi xture.
ENGINE MOUNTREAR
REMOVAL
(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
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.
(4) Remove transmi ssi on jack.
torque.
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.
(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
(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.
manifold.
(25) I nstal l an engi ne l i fti ng fi xture.
(26) Remove the engi ne front mount thru-bol ts.
(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.
(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
(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
(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.
(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-
(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
(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
(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
(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.
Fig. 17 Cylinder Head Cover Gasket
CYLINDER HEAD COVER GASKET
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.
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
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).
(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.
CYLINDER HEAD
REMOVAL
(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.
(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
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
(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
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
(18) I nstal l cl osed crankcase venti l ati on system.
(19) Connect the evaporati on control system.
System for proper procedure).
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
HYDRAULIC TAPPETS
REMOVAL
(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.
(9) Start and operate engi ne. Warm up to normal
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
(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
(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.
TIMING CHAIN COVER
REMOVAL
System).
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
(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
(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).
Cool i ng System).
Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
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
crankshaft bores.
shaft sprocket.
(6) I nstal l the camshaft bol t. Ti ghten the bol t to 68
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.
(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,
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
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.
crankshaft bores.
shaft sprocket.
(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
TIMING MARKS
Fig. 31 Camshaft Bearings Removal/Installationwith
Tool C-3132-A
SPECIAL TOOL C-3132A MAIN BEARING OIL HOLE
(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.
REMOVAL
(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.
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
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,
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
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
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).
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.
INSTALLATION
(1) Fabri cate 4 al i gnment dowel s from 5/16 x 1 1/2
(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.
onto the bl ock.
(6) I nstal l the oi l pan bol ts. Ti ghten the bol ts to 24
(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
5/16 X 1
1
2 BOLT DOWEL SLOT
(8) I nstal l the drai n pl ug. Ti ghten drai n pl ug to 34
(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/
(14) Move the cool er l i nes back i nto posi ti on.
l evel .
REMOVAL
(1) Remove the engi ne from the vehi cl e.
(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.
DOWEL DOWEL DOWEL DOWEL
(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.
(10) I nstal l the cyl i nder head.
CRANKSHAFT
REMOVAL
i ng cap.
(4) Remove the ti mi ng chai n cover.
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
(10) I nstal l oi l pump.
(11) I nstal l the ti mi ng chai n cover.
(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
(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
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
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.
(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.
damage the crankshaft seal bore of cover.
(Fi g. 43).
(Fi g. 44).
(9) I nspect the seal fl ange on the vi brati on
damper.
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. 43 Position Tool and Sealonto Crankshaft
SPECIAL TOOL 6635
TIMING
CHAIN
COVER
oi l .
oi l .
cati on.
UPPER SEAL CRANKSHAFT INSTALLED
REMOVAL
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.
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.
cati on. Be sure the whi te pai nt faces toward the rear
of the engi ne.
(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
(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
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.
LOWER SEAL
REMOVAL
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).
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.
cati on.
and oi l ed cap bol ts. Al ternatel y ti ghten the cap bol ts
pan seal groove.
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
(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.
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).
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
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
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:
(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.
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
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
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.
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.
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
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
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
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)
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 )
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
(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
(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)
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.
TORQUE
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
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
5.9L ENGINE
INDEX
page page
GENERAL INFORMATION
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . 92
SERVICE PROCEDURES
CRANKSHAFT SERVICE . . . . . . . . . . . . . . . . . 95
FITTING CRANKSHAFT MAIN BEARINGS . . . . 94
FITTING PISTON RINGS . . . . . . . . . . . . . . . . . 93
FITTING PISTONS . . . . . . . . . . . . . . . . . . . . . . 93
MEASURING TIMING CHAIN STRETCH . . . . . . 92
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . 92
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . 103
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 102
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . 104
CRANKSHAFT REAR OIL SEALS . . . . . . . . . . 109
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 107
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 98
DISTRIBUTOR DRIVE SHAFT BUSHING . . . . 104
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 97
ENGINE CORE OIL AND CAMSHAFT PLUGS . 110
ENGINE MOUNTSREAR . . . . . . . . . . . . . . . . 96
FRONT CRANKSHAFT OIL SEAL . . . . . . . . . . 108
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . 100
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
PISTON AND CONNECTING ROD
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 106
TIMING CHAIN COVER . . . . . . . . . . . . . . . . . 101
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . 102
VALVE SPRING AND STEM SEAL
REPLACEMENT-IN VEHICLE . . . . . . . . . . . . 98
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . 100
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . 113
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . 111
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 111
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
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.
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 .)
Torque . . . . . . . . 448 Nm (330 ft. l bs.) @ 3,250 rpm
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.)
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
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
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.
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.
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.
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.
F
i
g
.
3
O
i
l
L
u
b
r
i
c
a
t
i
o
n
S
y
s
t
e
m
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 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.
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.)
crankshaft bores.
shaft sprocket.
(11) I nstal l the camshaft bol t. Ti ghten the bol t to
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).
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
TIMING MARKS
PISTON PIN BORE DIAME- TER 25.007 - 25.015 mm (.9845 - .9848 IN.)
(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.
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
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
ENGINE MOUNTSFRONT
REMOVAL
(2) Posi ti on fan to assure cl earance for radi ator top
tank and hose.
manifold.
(3) I nstal l engi ne l i fti ng fi xture.
(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)
SILL BRACKET ASSEMBLY ENGINE SUP- PORT INSULA- TOR ASM. THROUGH-BOLT RIGHT SIDE
(a) RI GHT SI DEI nstal l the si l l bracket assem-
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-
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
(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.
(6) Remove l i fti ng fi xture.
ENGINE MOUNTSREAR
REMOVAL
(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
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
(5) Remove the transmi ssi on support.
torque.
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
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.
(11) Remove throttl e body.
(12) Remove the starter wi res.
(13) Remove the oi l pressure wi re.
(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-
(18) Remove the generator (refer to Group 8C,
Generator Servi ce).
(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.
manifold.
(25) I nstal l an engi ne l i fti ng fi xture.
(26) Remove the engi ne front mount thru-bol ts.
(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.
(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
(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
(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.
(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-
(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
(28) Warm engi ne and adjust.
(29) I nstal l hood and l i ne up.
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
(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.
(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.
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.
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.
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
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).
(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).
(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.
(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.
CYLINDER HEAD
REMOVAL
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.
Fig. 17 Cylinder Head Cover Gasket
CYLINDER HEAD COVER GASKET
Fig. 18 Rocker Arms
ROCKER ARMS CYLINDERHEAD
(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
down cabl es.
(10) Remove di stri butor cap and 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
(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
(8) I nstal l coi l wi res.
(9) Connect heat i ndi cator sendi ng uni t wi re.
(13) Connect the accel erator l i nkage and i f so
down cabl es.
(14) I nstal l the fuel l i nes.
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
(18) I nstal l cl osed crankcase venti l ati on system.
(19) Connect the evaporati on control system.
System for proper procedure).
REMOVAL
(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
(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
(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.
C-4129-A through openi ng i n cyl i nder head and seat
tool fi rml y i n the head of tappet.
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.
(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.
(7) I nstal l rocker arm.
become quiet.
VIBRATION DAMPER
REMOVAL
(2) Remove fan shroud retai ner bol ts and set
shroud back over engi ne.
(3) Remove the cool i ng system fan.
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
(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.
Cool i ng System).
Ti ghten the retai ner bol ts to 11 Nm (95 i n. l bs.)
torque.
TIMING CHAIN COVER
REMOVAL
System).
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).
(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.
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.
(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.
(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.
(9) I nstal l vi brati on damper.
Fig. 22 Removal of Front Crankshaft Oil Seal
Fig. 24 Position Tool and Seal onto Crankshaft
ZG 5. 9L ENGINE 9 - 101
(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).
Cool i ng System).
Ti ghten the bol ts to 11 Nm (95 i n. l bs.) torque.
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
crankshaft bores.
shaft sprocket.
(6) I nstal l the camshaft bol t. Ti ghten the bol t to 68
new thrust pl ate.
CAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 27).
REMOVAL
(2) Remove cyl i nder head covers.
(3) Remove ti mi ng case cover and ti mi ng chai n.
(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,
SPECIAL TOOL 6635
TIMING
CHAIN
COVER
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
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.
crankshaft bores.
shaft sprocket.
(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
TIMING MARKS
ZG 5. 9L ENGINE 9 - 103
Tool C-3132-A) at back of each beari ng shel l . Dri ve
out beari ng shel l s (Fi g. 31).
INSTALLATION
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.
correctl y. I nstal l a new core hol e pl ug at the rear of
camshaft. Be sure this plug does not leak.
REMOVAL
i ng cap.
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.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove di stri butor, refer to Group 8D, I gni ti on
(2) Remove the i ntake mani fol d (refer to Group 11,
(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
9 - 104 5. 9L ENGINE ZG
(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,
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
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
engi ne oi l .
(4) Remove the oi l fi l ter.
(5) Remove the starter (refer to Group 8B, Battery/
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.
INSTALLATION
(1) Fabri cate 4 al i gnment dowel s from 5/16 x 1 1/2
(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.
onto the bl ock.
Fig. 34 Distributor Driveshaft Bushing Installation
Fig. 35 Burnishing Distributor DriveshaftBushing
SPECIAL TOOLC-3053 BUSHING
Fig. 36 Position of Oil Pump Shaft Slot
DISTRIBUTORDRIVE
ZG 5. 9L ENGINE 9 - 105
(6) I nstal l the oi l pan bol ts. Ti ghten the bol ts to 24
(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
(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/
(14) Move the cool er l i nes back i nto posi ti on.
l evel .
REMOVAL
(1) Remove the engi ne from the vehi cl e.
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.
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.
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.
rai l gaps l ocated properl y (Fi g. 39).
5/16 X 1
1
2 BOLT DOWEL SLOT
DOWEL DOWEL DOWEL DOWEL
9 - 106 5. 9L ENGINE ZG
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.
bol ts, the l ong protector shoul d be i nstal l ed on the
numbered si de of 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 .
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.
CRANKSHAFT
REMOVAL
i ng cap.
(4) Remove the ti mi ng chai n cover.
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.
oi l .
oi l .
cati on.
(11) I nstal l the ti mi ng chai n cover.
OIL PUMP
REMOVAL
(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
(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
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.
(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.
damage the crankshaft seal bore of cover.
(Fi g. 43).
(Fi g. 44).
(9) I nspect the seal fl ange on the vi brati on
damper.
Fig. 43 Position Tool and Sealonto Crankshaft
SPECIAL TOOL 6635
TIMING
CHAIN
COVER
9 - 108 5. 9L ENGINE ZG
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.
oi l .
oi l .
cati on.
UPPER SEAL CRANKSHAFT INSTALLED
REMOVAL
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.
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
ZG 5. 9L ENGINE 9 - 109
cati on. Be sure the whi te pai nt faces toward the rear
of the engi ne.
and oi l ed cap bol ts. Al ternatel y ti ghten ALL cap bol ts
pan seal groove.
LOWER SEAL
REMOVAL
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).
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.
cati on.
and oi l ed cap bol ts. Al ternatel y ti ghten the cap bol ts
pan seal groove.
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
(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.
HYDRAULIC TAPPETS
DISASSEMBLE
(1) Pry out pl unger retai ner spri ng cl i p (Fi g. 49).
retai ner and pl unger spri ng (Fi g. 49). Check val ve
coul d be fl at or bal l .
ASSEMBLE
(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
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:
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
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
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:
(3) Remove the pi ston and connecti ng rod assem-
bl i es.
Fig. 56 Testing Valve Spring for CompressedLength
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
ASSEMBLE
(1) I nstal l the pi ston and connecti ng rod assembl y.
CYLINDER HEADS
CLEANING
Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
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.
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.
CRANKSHAFT JOURNALS
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
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
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.
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
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)
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)
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
(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
(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
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
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
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
Crankshaft Main Bearing Remover C-3059
Cylinder Bore Gauge C-119
9 - 122 5. 9L ENGINE ZG
ENGINE
CONTENTS
page page
GENERAL INFORMATION
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . 1
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 2
SERVICE DIAGNOSISDIESEL
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE DIAGNOSISDIESEL
MECHANICAL. . . . . . . . . . . . . . . . . . . . . . . . . 9
TAPPET NOISE . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE PROCEDURES
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 15
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . 19
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
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 38
PISTONS AND CONNECTING ROD
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CYLINDER WALL LINER ASSEMBLY . . . . . . . . 40
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPECIFICATIONS
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . 42
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.
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
SERVICE DIAGNOSISDIESELPERFORMANCE
ZG ENGINE 9 - 3
9 - 4 ENGINE ZG
ZG ENGINE 9 - 5
9 - 6 ENGINE ZG
ZG ENGINE 9 - 7
9 - 8 ENGINE ZG
SERVICE DIAGNOSISDIESELMECHANICAL.
ZG ENGINE 9 - 9
9 - 10 ENGINE ZG
ZG ENGINE 9 - 11
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
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
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.
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
(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.).
(7) Connect negati ve cabl e to battery
REMOVALLEFT SIDE
(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,
(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.).
(7) Connect negati ve cabl e to battery
Fig. 7 Front MountRight Side
Fig. 8 Front MountLeft Side
9 - 14 ENGINE ZG
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
(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
(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.
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).
(5) Remove the l ower radi ator hose.
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.
(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
(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.
servi ce val ves and cap the compressor ports (refer to
Group 14, Fuel System).
(17) Remove the power brake vacuum check val ve
(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).
(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.
(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.
(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
(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.
(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.
COOLANT CAN OCCUR.
Cool i ng).
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
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.
(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.
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
(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.
(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).
LOOSE CLOTHING.
unti l the thermostat opens. Add cool ant, i f requi red.
HYDRAULIC TAPPETS
REMOVAL
(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).
through openi ng i n bl ock and seat tool fi rml y i n the
head of tappet.
(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.
INSTALLATION
(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.
Fig. 14 Tappet And Rocker Arm Assembly
Fig. 15 Tappet And Yoke
9 - 18 ENGINE ZG
(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).
become quiet.
REMOVAL
(1) Di sconnect the battery cabl es.
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
INSTALLATION
(1) Rotate the crankshaft unti l the mark l i nes up
wi th the TDC mark on the ti mi ng cover.
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
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
(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.
REMOVAL
COOLANT CAN OCCUR.
Cool i ng).
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.
(10) Remove transmi ssi on crossmember bol ts, and
l ower rear of engi ne.
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,
(22) Remove I ntake mani fol d (refer to Group 11,
(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
(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).
(30) Remove rocker retai ni ng nuts (Fi g. 21).
(31) Remove rocker assembl y. Pl ace them on a
(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
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
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.
Fig. 25 Engine Cylinder Head Bolt Tightening Sequence
ZG ENGINE 9 - 23
(21) I nstal l transmi ssi on crossmember bol ts
(22) I nstal l exhaust down pi pe to turbocharger,
(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.
(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).
LOOSE CLOTHING.
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
(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
TIMING CASE COVER OIL SEAL
REMOVAL
(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
(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
(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,
(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).
CAMSHAFT
REMOVAL
(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.
(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,
(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
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,
(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).
LOOSE CLOTHING.
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
Beari ng Remover/I nstal l er Tool by sl i di ng the new
camshaft beari ng shel l over proper adapter.
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.
(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
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).
(7) Fi l l engi ne wi th proper amount of oi l .
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
(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
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
ZG ENGINE 9 - 29
(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
(2) Remove cyl i nder heads, refer to cyl i nder head
(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.
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.
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.
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
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
(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).
rai l gaps l ocated as shown i n (Fi g. 48).
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
(4) Face chamber recess si de of pi ston towards
camshaft.
bol ts.
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 .
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
(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
(1) Di sconnect battery cabl e.
(2) Remove engi ne from vehi cl e, refer to engi ne
(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.
(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
(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
(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
(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
(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.
HYDRAULIC TAPPETS
DISASSEMBLE
(1) Pry out pl unger retai ner spri ng cl i p.
retai ner and pl unger spri ng. Check val ve coul d be
fl at or bal l .
ASSEMBLE
(4) Assembl e tappets.
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
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
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
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
OIL PUMP
CLEANING
Wash al l parts i n a sui tabl e sol vent and i nspect
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
SPECIFICATIONS
ENGINE SPECIFICATIONS
9 - 42 ENGINE ZG
ZG ENGINE 9 - 43
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
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
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
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
Cylinder Head Bolt Wrench M12 VM. 1018
Cylinder Head Bolt Wrench M14 VM. 1019
Cylinder Leakage Tester Adapter VM. 1021
9 - 48 ENGINE ZG
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . 2
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . 2
EXHAUST SYSTEM DIAGNOSIS . . . . . . . . . . . . 3
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
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
EXHAUST SYSTEM DIAGNOSIS
EXHAUST PIPE
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(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
(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.
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
CATALYTIC CONVERTER
REMOVAL
(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
(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
(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.
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.
(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
(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
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.
(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
(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
(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
(11) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d. Di scard the seal .
(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
Fastener Numbers 6 and 7Ti ghten to 31 Nm
Fastener Numbers 8 through 11Ti ghten to 33
(7) I nstal l the fuel rai l and i njectors (refer to
(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.
(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.
Cool i ng System for the proper procedures).
(3) Remove the generator (refer to Group 8B Bat-
tery/Starti ng/Chargi ng Systems).
(5) Remove the fuel l i nes and fuel rai l (refer to
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.)
(6) Di sconnect the accel erator l i nkage and, i f so
down cabl es.
(8) Remove the di stri butor cap and 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.
torque.
torque.
Step 4Check that al l bol ts are ti ghten to 9.5
(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
(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).
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
(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,
Step 3Check that al l bol ts are ti ghten to 8
Step 4Ti ghten al l bol ts, i n sequence, to 16 Nm
Step 5Check that al l bol ts are ti ghten to 16
(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.
(15) Connect the accel erator l i nkage and, i f so
down cabl es.
(16) I nstal l the fuel l i nes and fuel rai l (refer to
(17) I nstal l the support bracket to the i ntake man-
i fol d and the mounti ng bracket.
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).
EXHAUST MANIFOLD5. 2/5. 9L ENGINE
REMOVAL
Exhaust mani fol ds are LOG type wi th bal anced
fl ow.
(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).
(5) Remove the bol ts and nuts attachi ng the
exhaust pi pe to the exhaust mani fol d.
(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
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
(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.
(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.
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.
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)
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.)
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
EXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . . 1
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
EXHAUST PIPE
REMOVAL
(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.
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.
REMOVAL
(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.
Fig. 2 Exhaust Down Pipe to Front Exhaust Pipe
Fig. 3 Front Pipe to Muffler
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
(18) Start the engi ne and check for l eaks.
INTAKE MANIFOLD
REMOVAL
(1) Remove exhaust mani fol d and turbocharger
assembl y.
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.
(9) Start engi ne and check for l eaks.
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
FRAME AND BUMPERS
CONTENTS
page page
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUMPERS
INDEX
page page
FRONT BUMPER/FASCIA . . . . . . . . . . . . . . . . . 1
REAR BUMPER FASCIA . . . . . . . . . . . . . . . . . . 2
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . 2
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
FRAME
INDEX
page page
GENERAL INFORMATION
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
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.
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
(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
(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
(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
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
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
(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
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)
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.
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.
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.
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.
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
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.)
FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . 3
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . 26
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
FUEL DELIVERY SYSTEM
INDEX
page page
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
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
PROCEDUREWITH PRESSURE TEST
PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL TUBES/LINES/HOSES AND CLAMPS . . . 11
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . 12
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
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.
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
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).
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
Thi s i s used to i denti fy each fuel i njector.
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
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
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.
RELEASE PROCEDURE.
Fig. 7 Fuel Pressure Test Port4.0LEngine
(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).
stal l ati on.
FUEL PUMP PRESSURE TEST 5. 2L/5. 9L
ENGINES WITHOUT PRESSURE TEST PORT
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:
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
(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).
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
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
Pressure Test and Fuel Pump Capaci ty Test.
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 ).
(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.
(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.
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
PROCEDUREWITH PRESSURE TEST PORT
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
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.
(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.
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
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.
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.
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.
THIS GROUP.
DISCONNECTION/CONNECTION
(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
(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.).
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.
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.
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
(1) Di sconnect negati ve battery cabl e from the bat-
tery.
secti on.
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.
(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.
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
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.
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.
THIS GROUP.
(1) Di sconnect negati ve battery cabl e from the bat-
tery.
secti on.
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.
(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.
FUEL LINE AT FUEL RAIL
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.
secti on.
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
(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.
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.
FUEL LINE AT FUEL RAIL5.2L ENGINES
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
tery.
secti on.
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
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.
fuel l i ne and fi tti ng (15-30 l bs.).
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
Fig. 23 Fuel Filter/Fuel Pressure RegulatorGasket
TOP OF MODULE
GASKET
Fig. 24 Fuel Filter/Fuel Pressure RegulatorO-Rings
TO FUEL INJECTORS
(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
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
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
I nstal l ati on.
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
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
I nstal l ati on.
FUEL INJECTOR RAIL 5. 2L/5. 9L ENGINES
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.
(4) Remove throttl e body from i ntake mani fol d.
Refer to Throttl e Body removal i n thi s group.
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
Fig. 29 Fuel Gauge Sending UnitRelease Tab
(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
Fig. 33 Fuel Injector MountingTypical
CLIP INJECTOR FUEL RAIL
FUEL INJECTOR RAIL 4. 0L ENGINE
REMOVAL
OFF. THIS PRESSURE MUST BE RELEASED
BEFORE SERVICING THE FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
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.
(10) Start engi ne and check for fuel l eaks.
FUEL INJECTOR(S)
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
(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
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.
FUEL TANK
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
(2) Rel ease fuel system pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group.
(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)
(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
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
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
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.
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.)
FUEL INJ ECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 27
MODES OF OPERATION . . . . . . . . . . . . . . . . . 27
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
SENSEPCM INPUT . . . . . . . . . . . . . . . . . . 31
BATTERY TEMPERATURE SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BATTERY VOLTAGEPCM INPUT . . . . . . . . . . 31
BRAKE SWITCHPCM INPUT . . . . . . . . . . . . . 32
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 32
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . . . 38
ENGINEPCM INPUT . . . . . . . . . . . . . . . . . 32
ENGINESPCM INPUT . . . . . . . . . . . . . . . . 32
DATA LINK CONNECTORPCM INPUT AND
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DUTY CYCLE EVAP PURGE SOLENOID
VALVE-PCM OUTPUT . . . . . . . . . . . . . . . . . . 38
4.0L ENGINEPCM INPUT . . . . . . . . . . . . . . 33
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
SENSOR4.0L ENGINEPCM INPUT . . . . . 34
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
SENSOR4.0L ENGINEPCM INPUT . . . . . 35
SENSOR5.2L/5.9L ENGINES
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 35
OIL PRESSURE SENSORPCM INPUT . . . . . 35
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 35
OVERDRIVE LAMPPCM OUTPUT . . . . . . . . . 41
OVERDRIVE/OVERRIDE SWITCH-PCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . 37
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
TRANSMISSION GOVERNOR PRESSURE
SENSORPCM INPUT . . . . . . . . . . . . . . . . . 36
TRANSMISSION PARK/NEUTRAL SWITCH
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 36
TRANSMISSION RELAYPCM OUTPUT . . . . . 41
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 36
VEHICLE SPEED AND DISTANCE SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 37
ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . 49
CAMSHAFT AND CRANKSHAFT POSITION
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2L/5.9L ENGINES . . . . . . . . . . . . . . . . . . . . 52
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . 53
SENSOR5.2L/5.9L ENGINE . . . . . . . . . . . . 53
SENSOR TEST4.0L ENGINE . . . . . . . . . . . 50
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
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.9L ENGINES . . . . . . . . . . . . . . . . . . . . . . . 54
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . 54
VISUAL INSPECTION4.0L ENGINE . . . . . . . . 46
VISUAL INSPECTION5.2L/5.9L ENGINES . . . 42
AIR CLEANER ELEMENT (FILTER) . . . . . . . . . 63
AIR CLEANER HOUSING . . . . . . . . . . . . . . . . . 62
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 55
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2L/5.9L ENGINES . . . . . . . . . . . . . . . . . . . . 64
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . 56
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . 65
SENSOR5.2L/5.9L ENGINES . . . . . . . . . . . 64
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . 60
SENSOR5.2L/5.9L ENGINES . . . . . . . . . . . 59
OXYGEN SENSOR4.0L ENGINE . . . . . . . . . . 62
OXYGEN SENSOR5.2L/5.9L ENGINES . . . . . 61
THROTTLE BODY4.0L ENGINE . . . . . . . . . . 57
THROTTLE BODY5.2L/5.9L ENGINES . . . . . . 56
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.9L ENGINES . . . . . . . . . . . . . . . . . . . . . . . 57
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
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
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
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)
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:
Battery vol tage
tor)
Battery vol tage
trans. onl y)
Oxygen sensors
Based on these i nputs, the fol l owi ng occurs:
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.
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
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:
Battery vol tage
tor)
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
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.
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
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.
Battery vol tage
tor)
trans. onl y)
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
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.
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
tor)
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
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.
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.
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.
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
Data l i nk connecti on for DRB scan tool
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)
Leak detecti on pump (swi tch) sense (i f equi pped)
Oi l pressure
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
Transmi ssi on governor pressure sensor
Transmi ssi on temperature 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
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.
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)
Fig. 3 Camshaft Position SensorTypical(5.2L/5.9L
Distributor Shown)
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.
ENGINE COOLANT TEMPERATURE SENSOR 5. 2L/
5. 9L ENGINES PCM INPUT
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
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)
Fig. 5 Crankshaft Position Sensor4.0LEngine
PIGTAIL HARNESS TO DIS- TRIBUTOR SIDE OF ENGINE
Fig. 6 Engine Coolant Temperature Sensor5.2L/
5.9LEngines
GENERATOR COOLANT TEMPERATURE SENSOR A/C COM- PRESSOR
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.
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.
4. 0L ENGINE PCM INPUT
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
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.
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.
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
THROTTLE POSITION SEN- SOR
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
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.
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
Typical
SENSOR ELECTRICAL CON- NECTOR 4WD TRANSFER CASE EXTENSION VEHICLE SPEED SENSOR
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
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
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
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.
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
recei ves.
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).
Thi s i s used to i denti fy each fuel i njector.
recei ves.
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
Fig. 16 Fuel Injectors4.0L Engine
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.
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
IGNITION COIL
MOUNTING BOLTS (2)
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 -
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.
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.
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
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. 25 Ignition Coil5.2L/5.9L Engines
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-
(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).
(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
Fig. 28 Sensor and IAC Motor Location5.2L/
5.9LEngines
MAP SENSOR
Fig. 29 Rubber L-Shaped FittingMAPSensor-to-
Throttle Body
MAP SENSOR
RUBBER FITTING
IDLE AIR PASSAGE
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.
5.9LEnginesTypical
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
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.
(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-
(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.
IGNITION COIL
MOUNTING BOLTS (2)
Fig. 38 Distributor and Wiring4.0LEngine
COIL CAMSHAFT POSITION SEN- SOR CONNECTOR DISTRIBUTOR
Fig. 39 Sensor Locations4.0L Engine
Throttle Body
THROTTLE BODY
MAP SENSOR
RUBBER FITTING
( )
(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).
(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.
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
Fig. 42 Upstream Oxygen Sensor4.0LEngine
EXHAUST DOWN PIPE OXYGEN SEN- SOR
Fig. 43 Downstream Oxygen Sensor4.0LEngine
CATALYTIC CONVERTER
CLIP
(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.
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.
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. 46 ASD and Fuel Pump Relay Terminals
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
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.
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-
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
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
(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-
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
Throttle Body
THROTTLE BODY
MAP SENSOR
RUBBER FITTING
( )
Fig. 52 Upstream Oxygen SensorLocation5.2L/
5.9L Engines
Fig. 53 Downstream Oxygen Sensor Location
AllEngines
CATALYTIC CONVERTER
CLIP
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-
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.
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
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:
temperature sensor (Fi g. 56).
Fig. 54 Upstream Oxygen Sensor Location
4.0LEngine
5.9LEngines
i nput i mpedance (di gi tal ) vol t-ohmmeter. The resi 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.
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
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:
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.
(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.
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
4.0LEngine
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:
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.
(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.
To perform a compl ete test of the sensor and i ts
ci rcui try, refer to DRB scan tool and appropri ate
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.
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
Fig. 59 TPS5.2L/5.9L Engines
MAP SENSOR
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.
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
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
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).
(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
(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.
Fig. 63 Power Distribution Center (PDC) Location
Fig. 64 Sensor Electrical Connectors5.2L/
5.9LEnginesTypical
MAP SENSOR
THROTTLE BODY 4. 0L ENGINE
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.
(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
(5) I nstal l control cabl es.
(6) I nstal l el ectri cal connectors.
ENGINES
REMOVAL
The TPS i s l ocated on the si de of the 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
Fig. 67 TPS Mounting Bolts5.2L/5.9LEngines
Typical
MOUNTING SCREWS
(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.
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.
ENGINES
The I AC motor i s l ocated on the back of the throt-
tl e body.
REMOVAL
(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
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)
(3) I nstal l el ectri cal connector.
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)
(4) I nstal l ai r cl eaner tube to throttl e body.
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
(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).
(4) Connect el ectri cal connector.
Fig. 72 Mounting Bolts (Screws)IACMotor4.0L
Engine
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
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).
(4) I nstal l ai r cl eaner i ntake tube.
DUTY CYCLE EVAP CANISTER PURGE SOLENOID
removal /i nstal l ati on procedures.
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
Throttle Body4.0L Engine
THROTTLE BODY
MAP SENSOR
RUBBER FITTING
( )
Fig. 77 Powertrain Control Module (PCM) Location
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
(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.
Refer to Group 8D, I gni ti on System for removal /i n-
stal l ati on procedures.
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.
(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
(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.
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.
(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.
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
Fig. 82 Upstream Oxygen Sensor Location
4.0LEngine
(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)
(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)
5. 9L ENGINES
REMOVAL
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
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.
5. 2L/5. 9L ENGINES
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
5.9LEngines
4.0LEngine
4. 0L ENGINE
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.
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
Typical
Fig. 90 Intake Air Sensor Location4.0LEngine
Typical
Typical
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
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.)
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
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
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
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
FUEL DELIVERY SYSTEM2.5L DIESEL ENGINE
INDEX
page page
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
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
HIGH-PRESSURE FUEL LINE LEAK TEST . . . . 13
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . 9
WASTEGATE (TURBOCHARGER) . . . . . . . . . . 14
SERVICE PROCEDURES
AIR BLEED PROCEDURES . . . . . . . . . . . . . . . 14
FUEL INJECTION PUMP TIMING . . . . . . . . . . . 15
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
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.
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
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
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
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
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
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.
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
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
WASTEGATE (TURBOCHARGER)
Refer to Group 11, Exhaust System and I ntake
Mani fol d for i nformati on.
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
(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.
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. 18 Vehicle Speed Sensor2 Wheel Drive
(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. 20 Engine Coolant Temperature Sensor Location
Fig. 21 Vacuum Pump at Generator
Fig. 22 Vaccum Pump at Front of Engine
(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
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.
clamped securely in place in the holders. The lines
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
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.
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.
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
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.
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.
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
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
(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
(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
REMOVAL
I nstal l ati on.
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
(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
(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
(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
Fig. 39 Injection Pump Mounting Nuts
Fig. 40 Access Plug at Rear of Pump
Fig. 41 Installing Dial Indicator and Special Adapter
Tools
(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
(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
(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
(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
(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.
(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
(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.
(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
(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.
(2) Drai n fuel tank dry i nto hol di ng tank or a
properl y l abel ed diesel safety contai ner.
(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
(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.
REMOVAL
(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
(4) Ti ghten each l i ne at the fuel i njector to 30 Nm
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
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 ).
FUEL INJ ECTION SYSTEM2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 26
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
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
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
ASD RELAY TEST . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . 36
DIESEL DIAGONSTICS . . . . . . . . . . . . . . . . . . 33
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
A/C CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . 36
ASD RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . 37
GLOW PLUG RELAY . . . . . . . . . . . . . . . . . . . . 38
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 38
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
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.
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
Low I dl e Posi ti on Swi tch
5 Vol t Suppl y
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
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
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
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.
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. 4 Engine Coolant Temperature Sensor Location
Fig. 5 Engine Speed Sensor Location
Fig. 6 Speed Sensor Operation
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. 8 Vehicle Speed SensorTypical
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
ENGINE OIL PRESSURE GAUGE PCM OUTPUT
Refer to the I nstrument Panel and Gauges group
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. 10 Glow Plug Lamp Symbol
Fig. 11 Fuel Timing Solenoid
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,
GLOW PLUG CONTROL
Fig. 13 Glow Plug
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.
i nformati on. See El ectri c Vacuum Modul ator.
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.
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 .
ENGINE COOLANT TEMPERATURE SENSOR TEST
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:
temperature sensor.
i nput i mpedance (di gi tal ) vol tohmmeter. The resi 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
Location
SENSOR RESISTANCE (OHMS)
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
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 .
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. 17 Wiring Connection at Glow Plug
GLOW PLUG CONTROL
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.
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
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 .
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.
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
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
(3) Connect the el ectri cal connector to the sensor.
REMOVAL
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.
(5) Repl ace any l ost engi ne cool ant. Refer to Group
7, Cool i ng System.
Fig. 19 Engine Speed Sensor
Location
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.
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
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.
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
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
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.
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
REMOVAL
(2) Cl ean the area around the sensor before
removal .
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.
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
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
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
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.
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
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
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
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
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
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
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
POWER STEERING PUMP
INDEX
page page
POWER STEERING PUMP . . . . . . . . . . . . . . . . 4
PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
POWER STEERING PUMPINITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
POWER STEERING PUMP 5.2L/5.9L . . . . . . . 6
POWER STEERING PUMP 4.0L . . . . . . . . . . . . 6
PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . 7
TC-SERIES PUMP RESERVOIR . . . . . . . . . . . . . 7
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS
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.
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
(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.
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
(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.
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
(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
POWER STEERING GEAR
INDEX
page page
POWER STEERING GEAR . . . . . . . . . . . . . . . . 9
POWER STEERING GEAR LEAKAGE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . 11
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . 12
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . 12
RACK PISTON AND WORM SHAFT . . . . . . . . . 16
SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 13
ADJUSTMENTS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIAL TOOLS
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.
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
POWER STEERING GEAR LEAKAGE DIAGNOSIS
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
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
(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
(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
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
(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
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
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
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . 22
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.
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).
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.
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
(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
(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
(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
STEERING LINKAGE
INDEX
page page
GENERAL INFORMATION
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . 25
SERVICE PROCEDURES
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STEERING DAMPENER . . . . . . . . . . . . . . . . . . 27
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIAL TOOLS
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.
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
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).
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
STEERING
CONTENTS
page
SPEED PROPORTIONAL STEERING . . . . . . . . . . 1
INDEX
page page
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPEED PROPORTIONAL STEERING . . . . . . . . . 1
STEERING WHEEL SPEED SENSOR . . . . . . . . 2
SPEED PROPORTIONAL STEERING . . . . . . . . . 3
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING WHEEL SPEED SENSOR . . . . . . . . 3
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
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.
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
For di agnosi s and testi ng procedures refer to the
Chassi s Di agnosti c Manual .
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.
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
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
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
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
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
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
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1
4
2
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4
4
R
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i
s
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i
o
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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.
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
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
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.
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
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.
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.
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.
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.
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
(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.
(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.
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
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
(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.
(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.
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
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
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.
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
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.
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.
transmission. Replace overrunning
clutch.
6. Input Shaft Seal Rings Worn/
Damaged.
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.
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.
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.
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
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
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.
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.
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.
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.
SLIPS IN OVERDRIVE FOURTH
GEAR
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)
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.
NO REVERSE (OR SLIPS IN
REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch
pack.
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.
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
(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
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
(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.
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.
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
(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)
(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.
(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
(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
(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
SPEEDOMETER ADAPTER
Rear axl e gear rati o and ti re si ze determi ne speed-
ometer pi ni on requi rements.
REMOVAL
(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
(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
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.
(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.
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,
(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
(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
(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
(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
(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
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.
(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
(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
(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
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
(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
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
(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
(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
(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
(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
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
Fig. 44 Governor Body And Retainer PlateAttaching
Screw
Fig. 45 Governor Body And Gasket
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. 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
(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
(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) 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
(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
(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
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
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
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
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
(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
(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
(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
(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
Fig. 85 Upper Housing Control Valve Locations
Fig. 86 Upper Housing Shift Valve And PressurePlug Locations
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
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
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.
(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. 97 Governor Pressure Solenoid
(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
Fig. 99 Pressure Solenoid Retainer
Fig. 100 Governor Pressure Sensor And
SolenoidConnectors
Fig. 101 Oil Filter Removal
OIL FILTER VALVE BODY FILTER SCREWS (3)
Fig. 102 Valve Body Bolt Locations
VALVE BODY BOLTS
VALVE BODY
BOLTS
(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
(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
(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
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
(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
(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
(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
(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
(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
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
(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
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
(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
(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
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
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
(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
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
(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
(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
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
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
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
(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
(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
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
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
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
(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
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
(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) 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
(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
(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
(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
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
(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
(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
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
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
(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
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
(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
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
(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
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
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
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
(4) Posi ti on Seal Gui de 8114-2 on i nner edge of
(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).
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)
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
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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
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.
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)
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.
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
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
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
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
(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
(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.
(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-
REAR BAND ADJ USTMENT
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(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)
Hol d adjusti ng screw i n pl ace and ti ghten l ock-
44RE TRANSMISSION
Back off adjusti ng screw 4 turns.
Hol d adjusti ng screw i n pl ace and ti ghten l ock-
(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)
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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
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.
SPECIAL TOOLS
RE TRANSMISSIONS
Spring Compressor and Alignment Shaft6227
Gauge Bar6311
Extension Housing PilotC-3288-B
Pressure GaugeC-3292
Pressure GaugeC-3293SP
Spring CompressorC-3422-B
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
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
Gauge6312
AdapterC-3705
Flusher6906
Installer8114
Remover6957
Installer6951
Retainer6583
NV242 TRANSFER CASE
INDEX
page page
GENERAL INFORMATION
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . 123
RECOMMENDED LUBRICANT AND FILL LEVEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
TRANSFER CASE IDENTIFICATION . . . . . . . . 124
NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 125
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . 128
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . 127
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . 127
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . 126
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . 129
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
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 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
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.
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
(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.
(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
(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.
(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.
(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.
(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
as an assembl y.
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
Repl ace pi ni on i f chi pped, cracked, or worn.
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
INSTALLATION AND INDEXING
ati on.
ometer adapter (Fi g. 5), i f necessary.
pi ni on.
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
i n. l bs.) torque.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(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
(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.
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
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
(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
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
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
(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
(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
(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
Fig. 38 Sector Bushing And O-Ring Removal
SHIFT SEC- TOR BUSHING O-RING
(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
(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)
(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
(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. 51 Install Front Output Shaft Seal
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
(10) I nstal l new pi l ot beari ng wi th I nstal l er 8128
(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
(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)
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
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
(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
(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
(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
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).
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
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
(4) I nstal l yoke on front shaft. Secure yoke wi th
new nut.
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
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
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.
(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.
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
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
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
Installer8128
Installer5066
Installer6952-A
RemoverL-4454
Cup8148
Seal Protector6992
Installer, Input Gear Bearing7829-A
Installer, Seal7884
Installer, Pump Housing Seal7888
Installer, Bearing8033-A
Installer, Boot ClampC-4975-A
NV249 TRANSFER CASE
INDEX
page page
GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . 155
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
TRANSFER CASE IDENTIFICATION . . . . . . . . 155
NV249 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 156
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . 160
REAR RETAINER BUSHING AND SEAL . . . . . 160
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . 158
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . 158
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . 157
NV249 TRANSFER CASE . . . . . . . . . . . . . . . . 161
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.
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.
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
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.
TRANSFER CASE
REMOVAL
(6) Remove rear crossmember, or ski d pl ate.
fer case.
range l ever.
mi ssi on.
gage transfer case.
INSTALLATION
to 35 Nm (26 ft. l bs.) torque (Fi g. 3).
hose.
on transfer case.
shaft attachi ng bol ts to 19 Nm (170 i n. l bs.) torque.
(10) I nstal l rear crossmember, or ski d pl ate.
Ti ghten crossmember bol ts to 41 Nm (30 ft. l bs.)
torque.
operati on.
VENT TUBE TRANSFER CASE TRANSMISSION
SHIFT LEVER
REMOVAL
(3) Loosen adjusti ng trunni on l ocknut and sl i de
torque shaft.
(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.
(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
as an assembl y.
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
TORQUE
(2735 in. lbs.)
(97123 in. lbs.)
(72120 in. lbs.)
ati on.
pi ni on.
i n. l bs.) torque.
ITEM TORQUE
A 2-3 Nm (15-27 in. lbs.)
B 10-12 Nm (90-110 in. lbs.)
ITEM
Fig. 6 Location Of Index Numbers On
SpeedometerAdapter
REMOVAL
7).
INSTALLATION
REAR RETAINER BUSHING AND SEAL
REMOVAL
(2) Remove rear propel l er shaft. Refer to Group 3,
(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 .
Fig. 9 Rear Retainer Bushing Removal
REMOVER 6957 REAR RETAINER BUSHING
Fig. 10 Rear Retainer Bushing Install
INSTALLER 8145 REAR RETAINER BUSHING
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
(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
(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
(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
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
Fig. 35 Front Bearing Retainer Removal
FRONT BEARING RETAINERRETAINER NOTCH FLAT BLADE SCREW- DRIVER
INPUT GEAR SNAPRING
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. 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
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.
(a) Pl ace new seal on tool . Garter spring on
seal goes toward interior of case.
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. 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
(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
(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
(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
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
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
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.
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
(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
(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 .
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
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
FINAL ASSEMBLY
(1) I nstal l drai n pl ug. Ti ghten pl ug to 41-54 Nm
(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
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
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
(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
(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.)
SPECIAL TOOLS
NV249 TRANSFER CASE
Installer5066
Installer6952-A
Installer6953
Remover6957
InstallerC-3995-A
HandleC-4171
Installer8145
RemoverC-4210
RemoverL-4454
Cup8148
Installer8128
Installer7884
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
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.
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
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.
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
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
Fig. 10 Transmission to Engine Mounting
Fig. 11 Clutch Housing to Transmission
Fig. 12 Fill Plug Location
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Cl utch Housi ng to Engi ne
Top (2) Bol ts . . . . . . . . . . . . 36.6 Nm (27 ft. l bs.)
Mi d-Poi nt (2) Bol ts . . . . . . . 58.3 Nm (43 ft. l bs.)
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.)
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.
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.
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
NV231 DIAGNOSIS
TRANSFER CASE
REMOVAL
(6) Remove rear crossmember and ski d pl ate, i f
equi pped.
fer case.
range l ever.
mi ssi on.
gage transfer case.
INSTALLATION
to 35 Nm (Fi g. 2).
hose.
on transfer case.
shaft attachi ng bol ts to 26.5 Nm torque.
(10) I nstal l rear crossmember and ski d pl ate, i f
equi pped. Ti ghten crossmember bol ts.
operati on.
SHIFT LEVER
REMOVAL
(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.
(6) Loosen adjusti ng trunni on l ock bol t and sl i de
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. 3 Shift Lever
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.
(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
as an assembl y.
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.
ati on.
pi ni on.
i n. l bs.) torque.
REMOVAL
6).
INSTALLATION
I nstal l er Tool 8143 as fol l ows:
REAR RETAINER BUSHING AND SEAL
REMOVAL
(2) Remove rear propel l er shaft. Refer to Group 3,
(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. 8 Rear Retainer Bushing Removal
(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 .
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
TIRES AND WHEELS
CONTENTS
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRES
INDEX
page page
RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . . . 2
REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . 3
SPARE TIRE (TEMPORARY) . . . . . . . . . . . . . . . 2
TIRE INFLATION PRESSURES . . . . . . . . . . . . . 2
TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . 1
TIRE PRESSURE FOR HIGHSPEED
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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 OF TIRES . . . . . . . . . . . . . . . . . . . . 6
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
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.
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
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
(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
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
WHEELS
INDEX
page page
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . 8
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
TIRE AND WHEEL BALANCE . . . . . . . . . . . . . . . 9
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 10
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.
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
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
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
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
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
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 4
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . 7
QUARTER WINDOW GLASS . . . . . . . . . . . . . . . 5
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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.
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
(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.
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
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.
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
POWER SUNROOF
INDEX
page page
GENERAL INFORMATION
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
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.
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
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
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
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.
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
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
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
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
(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
(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.
(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
(7) Engage cl i ps attachi ng seat cover to each si de
(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
(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
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
BODY COMPONENTS
INDEX
page page
UNIVERSAL TRANSMITTER . . . . . . . . . . . . . . 18
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 17
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE PROCEDURES
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . 18
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
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
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.
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
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
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
(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
(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 .
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
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 -
(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
(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).
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
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
INSTALLATION
FRONT DOOR LATCH
REMOVAL
(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.
FRONT DOOR INSIDE HANDLE ACTUATOR
REMOVAL
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
INSTALLATION
FRONT DOOR INNER BELT SEAL
REMOVAL
(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
(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
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
(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
FRONT DOOR WINDOW GLASS
REMOVAL
(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
(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
(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 -
(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
(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).
Fig. 28 Rear Door Trim Panel
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
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
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
REAR DOOR LATCH
REMOVAL
(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
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
(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
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
REAR DOOR INNER BELT SEAL
REMOVAL
(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
(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
(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
REAR DOOR WINDOW GLASS
REMOVAL
(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
(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
(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
(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
(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
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
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
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
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
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
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
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.
(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.
(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
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
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
(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
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
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
(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
(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.
(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
ZG BODY 23 - 41
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
LIFTGATE LATCH STRIKER
REMOVAL
(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
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
FLIP-UP GLASS SWITCH
REMOVAL
(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.
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
(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
(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
(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.
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
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
(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
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
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . 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
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
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.
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
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.
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.
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).
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.
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
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
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
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.
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
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
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
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
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
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.
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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.
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
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
Circuit Testing (cont.)
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
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
BLOWER MOTOR
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
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
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.
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
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 ).
(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
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.
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:
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
i ng Di agrams.
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
(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
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
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
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.
i ng Di agrams.
(1) Veri fy that the refri gerant system i s properl y
charged.
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.
RELAY TEST
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:
RELAY CIRCUIT TEST
i ng Di agrams.
ci rcui t to the Power Di stri buti on Center (PDC) fuse
as requi red.
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
the bl ower motor as requi red.
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.
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
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
grams, refer to 8W-42 - Ai r Condi ti oni ng/Heater i n
(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
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
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
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
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
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
(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
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
REFRIGERANT LINE COUPLER
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.
REMOVAL
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
(3) Unpl ug the compressor cl utch coi l wi re harness
connector.
(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.
(7) Evacuate and charge the refri gerant system as
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.
REMOVAL
cabl e.
(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
(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
(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.).
(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.
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
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).
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
(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.
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
(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
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
(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.).
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.
cabl e.
(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
REMOVAL
cabl e.
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.
Fig. 30 Check Air Gap
FEELER GAUGE
NEGATIVE CABLE
Fig. 32 High Pressure Cut-Off Switch - Typical
MANIFOLD HIGH PRESSURE SERVICE PORT HIGH PRESSURE CUTOUT SWITCH DISCHARGELINE SUCTION LINE
HIGH PRESSURE RELIEF VALVE
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve cabl e.
(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.
CONDENSER
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
cabl e.
(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
(4) Remove the radi ator gri l l e panel . Refer to
(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
(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.
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
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
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.
REMOVAL
cabl e.
(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.
ACCUMULATOR
REMOVAL
cabl e.
(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
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.
NOTE: If the accumulator is replaced, add 120 ml (4
oz.) of refrigerant oil to the refrigerant system.
cabl e.
swi tch.
(3) Unscrew the swi tch from the fi tti ng on the
accumul ator.
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.
Fig. 37 Accumulator and Bracket
CLUTCH CYCLING PRES- SURE SWITCH ACCUMULATOR SUPPORT BRACKET
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.
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.
HEATER-A/C CONTROL
INJURY.
REMOVAL
cabl e.
bl aded tool , pry gentl y around the edges of the
(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
(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 .
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.
INJURY.
REMOVAL
cabl e.
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 .
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. 43 Solar Sensor
DEFROST GRILLE SOLAR SENSOR SOLAR SENSOR CONNECTOR
INJURY.
REMOVAL
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
BLOWER MOTOR
REMOVAL
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
(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.
BLOWER MOTOR RESISTOR AND POWER
MODULE
REMOVAL
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.
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.
INJURY.
REMOVAL
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
(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.
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
cabl e.
motor (Fi g. 50).
(3) Remove the screws that secure the motor to the
(4) Remove the temperature/bl end ai r door motor.
INSTALLATION
(1) Posi ti on the motor over the door connecti on.
motor to the heater-A/C housi ng.
motor.
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.
defroster duct to the i nstrument panel armature.
(3) Remove the defroster duct.
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.
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.
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
(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.
DEMISTER OUTLETS
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.
PANEL/DEFROST DOOR
REMOVAL
cabl e.
(2) Remove the i nstrument panel as descri bed i n
(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
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
RECIRCULATING AIR DOOR ACTUATOR
REMOVAL
cabl e.
(2) Remove the i nstrument panel as descri bed i n
(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
(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.
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
HEATER-A/C HOUSING
REMOVAL
cabl e.
(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
(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
(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
(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
(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
(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
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.
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
cl e as descri bed i n thi s group.
(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.
(6) Remove the heat/defrost door actuator.
INSTALLATION
(1) I nstal l the heat/defrost door actuator.
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
(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.
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
thi s group.
panel /defrost door actuator (Fi g. 62).
(3) Separate the actuator door pi vot connecti on
from the door pi vot pi n.
(5) Remove the panel /defrost door actuator.
INSTALLATION
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.
actuator.
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
cl e as descri bed i n thi s group.
motor (Fi g. 63).
(4) Remove the screws that secure the motor to the
(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.
motor to the housi ng.
motor.
thi s group.
HEAT/DEFROST DOOR
REMOVAL
thi s group.
(3) Separate the actuator door pi vot connecti on
from the door pi vot pi n.
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
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.
onto the bottom. Be certai n the door pi vot pi ns al i gn
wi th the pi vot hol es.
I nstal l and ti ghten the screws.
actuator, or the wi re harness connector to the motor,
as equi pped.
thi s group.
RECIRCULATING AIR DOOR
REMOVAL
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.
thi s group.
TEMPERATURE/BLEND AIR DOOR
REMOVAL
thi s group.
(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.
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.
I nstal l and ti ghten the screws.
thi s group.
Fig. 64 Temperature Control (Blend Air) Door
HEAT/DEFROST DOOR TEMP/BLEND AIR DOOR
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
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
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.
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.
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
25 - 2 EMISSION CONTROL SYSTEMS ZG
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 .
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
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
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
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.
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
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
or
Circuit
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.
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
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
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
or
Circuit
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
or
Circuit
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
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
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.
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
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
HEX
CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
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
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
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.
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-
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
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
EVAPORATIVE EMISSION CONTROLS
INDEX
page page
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
LEAK DETECTION PUMP (LDP) . . . . . . . . . . . 18
PCV VALVE TEST5.2L/5.9L ENGINE . . . . . . . 17
VACUUM SCHEMATICS . . . . . . . . . . . . . . . . . . 18
EVAPORATIVE (EVAP) CANISTER . . . . . . . . . . 18
EVAPORATIVE CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LEAK DETECTION PUMP (LDP) . . . . . . . . . . . 19
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 20
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
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
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
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
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 .
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
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.
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
INSTALLATION
(1) Posi ti on cani ster to body.
(2) I nstal l cani ster mounti ng nuts. Ti ghten nuts to
(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).
(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
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.)
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
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.
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
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
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
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
EXHAUST EMISSION CONTROLS2.5L DIESEL ENGINE
INDEX
page page
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VACUUM HOSE ROUTING SCHEMATIC . . . . . . 5
EGR GAS FLOW TEST . . . . . . . . . . . . . . . . . . . 6
ELECTRIC VACUUM MODULATOR (EVM) TEST . . 6
EGR TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRIC VACUUM MODULATOR (EVM) . . . . . 7
SPECIFICATIONS
TORQUE CHART2.5L DIESEL . . . . . . . . . . . . 8
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
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.
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
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
(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
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.)

1997 JEEP GRAND CHEROKEE SERVICE MANUAL

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1997 JEEP GRAND CHEROKEE SERVICE MANUAL

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1997 J eep Grand Cherokee

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