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Jeep 1997 Grand Cherokee Service Manual

Manual is about: 1997 Jeep Grand Cherokee(RHD & LHD) Interactive Electronic Service Manual

Summary of 1997 Grand Cherokee

  • Page 1

    Welcome to the 1997 jeep grand cherokee (rhd & lhd) interactive electronic service manual! Click on vehicle to begin tweddle litho: dom parts cdrom demo 09/96 page 4.

  • Page 2

    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 fl...

  • Page 3: Introduction

    Introduction contents page page general information body code plate . . . . . . . . . . . . . . . . . . . . . 2 fastener identification . . . . . . . . . . . . . . . 3 international vehicle control and display symbols . . . . . . . . . . . . . . . . . . . . 3 metric system . . . . . . . . . . . . . ...

  • Page 4

    Vehicle safety certification label a vehicle safety certification label (fig. 1) is attached to every chrysler corporation vehicle. The label certifies that the vehicle conforms to all appli- cable federal motor vehicle safety standards. The label also lists: • month and year of vehicle manufacture....

  • Page 5

    International vehicle control and display symbols international vehicle control and display symbols the graphic symbols illustrated in the following chart (fig. 3) are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument...

  • Page 6

    Fastener identification 4 introduction zg general information (continued).

  • Page 7

    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...

  • Page 8

    Metric system warning: use of an incorrect fastener may result in component damage or per- sonal injury. Figure art, specifications and torque references in this service manual are identified in metric and sae format. During any maintenance or repair procedures, it is important to salvage metric fas...

  • Page 9

    Metric conversion zg introduction 7 general information (continued).

  • Page 10

    Torque specifications specified torque for standard bolts class diameter mm pitch mm specified torque hexagon head bolt hexagon flange bolt n·m kgf-cm ft.-lbf n·m 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 general information (continued).

  • Page 11: Introduction

    Introduction contents page general information vehicle identification number (vin) . . . . 1 general information vehicle identification number (vin) the vehicle identification number (vin) plate is attached to the top left side of the instrument panel. The vin contains 17 characters that provide dat...

  • Page 13

    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 . . . . . . ....

  • Page 14

    Engine oil sae grade rating indicates engine oil viscosity an sae viscosity grade is used to specify the vis- cosity of engine oil. Sae 30 specifies a single viscos- ity engine oil. Engine oils also have multiple viscosities. These are specified with a dual sae vis- cosity grade which indicates the ...

  • Page 15

    Maintenance schedules index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 3 schedule—a . . . . . . . . . . . . . . . . . . . . . . . . . 3 schedule—b . . . . . . . . . . . . . . . . . . . . . . . . . 5 unscheduled inspection . . . . . . . . . . . . . . 3 ...

  • Page 16

    • replace spark plugs. • inspect drive belt. • lubricate steering linkage. • drain and refill automatic transmission fluid. • drain and refill transfer case fluid. 37,500 miles (60 000 km) or at 30 months • change engine oil. • replace engine oil filter. • lubricate steering linkage (4x4 only). 45,0...

  • Page 17

    **recommended for proper vehicle performance for vehicles built for sale in california. Important: inspection and service should also be performed anytime a malfunction is observed or suspected. Schedule—b 3,000 miles (5 000 km) • change engine oil. • replace engine oil filter. • lubricate steering ...

  • Page 18

    51,000 miles (82 000 km) • change engine oil. • replace engine oil filter. • flush and replace engine coolant. • lubricate steering linkage (4x4 only). 54,000 miles (86 000 km) • change engine oil. • replace engine oil filter. • lubricate steering linkage (4x4 only). 57,000 miles (91 000 km) • chang...

  • Page 19

    • inspect brake linings. 99,000 miles (158 000 km) • change engine oil. • replace engine oil filter. • lubricate steering linkage (4x4 only). 102,000 miles (163 000 km) • change engine oil. • replace engine oil filter. • lubricate steering linkage (4x4 only). 105,000 miles (168 000 km) • change engi...

  • Page 20

    Jump 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 . . . . . ....

  • Page 21

    Onds, stop cranking engine and allow starter to cool (15 min.), before cranking again. Disconnect cable clamps as follows: • disconnect black cable clamp from engine ground on disabled vehicle. • when using a booster vehicle, disconnect black cable clamp from battery negative terminal. Disconnect re...

  • Page 22

    2wd—automatic transmission provided the transmission is operable, tow only in neutral at speeds not to exceed 30 mph (50 km/h) and distances less than 15 miles (25km/h). If the vehicle is to be towed more than 15 miles, the propeller shaft should be disconnected or place tow dollies under rear wheel...

  • Page 23

    Lubrication and maintenance contents page page general information . . . . . . . . . . . . . . . . . . 1 maintenance schedule . . . . . . . . . . . . . . . . . 2 general information index page page specifications engine oil—diesel engines . . . . . . . . . . . . 1 fluid capacities . . . . . . . . . ...

  • Page 24

    Maintenance schedule index page page general information maintenance schedule—diesel engine . 2 schedule—a . . . . . . . . . . . . . . . . . . . . . . . . . . 2 schedule—b . . . . . . . . . . . . . . . . . . . . . . . . . . 3 general information maintenance schedule—diesel engine the following are e...

  • Page 25

    60 000 km • change engine oil. • change engine oil filter. • replace air filter element. • check glow plug operation. • replace drive belt. • check engine smoke. • replace engine coolant. 70 000 km • change engine oil. • change engine oil filter. 80 000 km • change engine oil. • change engine oil fi...

  • Page 26

    • check glow plug operation. • replace fuel filter/water separator element. 45 000 km • change engine oil. • change engine oil filter. 50 000 km • change engine oil. • change engine oil filter. • replace air filter element. • check drive belt tension. • check glow plug operation. 55 000 km • change ...

  • Page 27: Suspension

    Suspension contents page page alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 front suspension . . . . . . . . . . . . . . . . . . . . . 4 rear suspension . . . . . . . . . . . . . . . . . . . . . 11 alignment index page page general information wheel alignment . . . . . . . . . ...

  • Page 28

    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 trust angle angle of rear axle relative t...

  • Page 29

    Diagnosis and testing pre-alignment inspection before starting wheel alignment, the following inspection is necessary and must be completed. (1) inspect tires for size, air pressure and tread wear. (2) inspect front wheel bearings for wear or adjust- ment. (3) inspect front wheels and tires for exce...

  • Page 30

    Front suspension index page page description and operation front suspension . . . . . . . . . . . . . . . . . . . . 4 diagnosis and testing shock diagnosis . . . . . . . . . . . . . . . . . . . . . 5 removal and installation axle bushing . . . . . . . . . . . . . . . . . . . . . . . . . 7 coil sprin...

  • Page 31

    Replaceable ball studs attached to the axle tube yokes. Shock absorbers: the shock absorbers dampen jounce and rebound motion of the vehicle over vari- ous road conditions. The top of the shock absorbers are bolted to the body. The bottom of the shocks are bolted to the axle brackets. Coil springs: ...

  • Page 32

    (5) disconnect the stabilizer bar link and shock absorber from the axle. (6) disconnect the track bar from the frame rail bracket. (7) disconnect the drag link from the pitman arm. (8) lower the axle until the spring is free from the upper mount. Remove the coil spring retainer bolt (fig. 2) and rem...

  • Page 33

    (7) tighten the frame bracket nut to 176 n·m (130 ft. Lbs.). (8) check the alignment if new parts were installed. Upper suspension arm removal (1) raise and support the vehicle. (2) remove the upper suspension arm nut and bolt at the axle bracket (fig. 4). (3) remove the nut and bolt at the frame ra...

  • Page 34

    (2) remove upper link nuts (fig. 7) and separate links from the stabilizer bar with remover mb-990635. (3) remove the stabilizer bar clamps bolts from the frame rails and remove the stabilizer bar. (4) remove the stabilizer bar link nuts from the axle brackets (fig. 7). Installation (1) position the...

  • Page 35

    (5) remove the hub mounting bolts and remove hub bearing from the steering knuckle and axle shaft. Installation (1) install the hub bearing and brake dust shield to the knuckle. (2) install the hub to knuckle bolts and tighten to 102 n·m (75 ft. Lbs.). (3) install the hub washer and nut. Tighten the...

  • Page 36

    Specifications torque chart description torque shock absorber upper nut . . . . . . . . . . . . . . . . 23 n·m (17 ft. Lbs.) lower nut . . . . . . . . . . . . . . 28 n·m (250 in. Lbs.) suspension arm upper nuts . . . . . . . . . . . . . . . . . . . . 75 n·m (55 ft. Lbs.) suspension arm lower axle br...

  • Page 37

    Rear suspension index page page description and operation rear suspension . . . . . . . . . . . . . . . . . . . . 11 diagnosis and testing shock diagnosis . . . . . . . . . . . . . . . . . . . . 12 removal and installation coil spring . . . . . . . . . . . . . . . . . . . . . . . . . 12 lower suspen...

  • Page 38

    Diagnosis and testing shock diagnosis a knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts. If the noise persists, inspect for damage...

  • Page 39

    Lower suspension arm removal (1) raise and support the vehicle. (2) remove the lower suspension arm nut and bolt at the axle bracket (fig. 3). (3) remove the nut and bolt (fig. 3) at the frame rail and remove the lower suspension arm. Installation (1) position the lower suspension arm at the axle br...

  • Page 40

    Track bar removal (1) raise and support the vehicle. (2) remove the bolt and nut from the frame rail bracket (fig. 5). (3) remove the bolt from the axle tube bracket (fig. 5). Remove the track bar. Installation (1) install the track bar to the axle bracket and install a new bolt. (2) it may be neces...

  • Page 41: Suspension

    Suspension contents page page alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 front suspension . . . . . . . . . . . . . . . . . . . . . 6 rear suspension . . . . . . . . . . . . . . . . . . . . . 14 alignment index page page general information wheel alignment . . . . . . . . . ...

  • Page 42

    Service procedures pre-alignment before starting wheel alignment, the following inspection and necessary corrections must be com- pleted. Refer to suspension and steering system diagnosis chart for additional information. (1) inspect tires for size, air pressure and tread wear. (2) inspect front whe...

  • Page 43

    Wheel alignment before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down three times. Always release the bumper in the down position. Camber the wheel camber angle is preset. This angle is not adjustable ...

  • Page 44

    Caster can be adjusted by loosening and rotating the cams on the lower suspension arm (fig. 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 p...

  • Page 45

    • vehicles with 2.5l engine: 27 n·m (20 ft. Lbs.) • vehicles with 4.0l engine: 27 n·m (20 ft. Lbs.) • vehicles with 5.2l engine: 49 n·m (36 ft. Lbs.) note: make sure the toe setting does not change during clamp tightening. (4) adjust the right wheel toe position with the tie rod. Turn the sleeve unt...

  • Page 46

    Front suspension index page page description and operation front suspension . . . . . . . . . . . . . . . . . . . . 6 diagnosis and testing shock diagnosis . . . . . . . . . . . . . . . . . . . . . 7 removal and installation axle bushing . . . . . . . . . . . . . . . . . . . . . . . . . 9 coil sprin...

  • Page 47

    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. Diagnosis and testing shock diagnosis a knocking or rattling noise from a shock absorber may be caused by movement between ...

  • Page 48

    Removal and installation shock absorber removal (1) remove the nut, retainer and grommet from the upper stud in the engine compartment (fig. 2). (2) remove the lower nuts and bolts from the axle bracket. Remove the shock absorber. Installation (1) position the lower retainer and grommet on the upper...

  • Page 49

    Installation (1) position the lower suspension arm at the axle bracket and frame rail bracket. (2) install the rear bolts and finger tighten the new nuts. (3) install a new cam bolt, cam and new nut in the axle. Re-align the reference marks. (4) install the bolts and finger tighten the new nuts. (5)...

  • Page 50

    Installation (1) position new bushing, receiver and installer on axle (fig. 6). (2) install the bushing by tightening the long nut. (3) remove tools and install the upper suspension arm. Stabilizer bar removal (1) raise and support the vehicle. (2) remove upper link bolts (fig. 7) and separate links...

  • Page 51

    Hub bearing removal (1) raise and support the vehicle. (2) remove the wheel and tire assembly. (3) remove the brake caliper, rotor and abs wheel speed sensor, refer to group 5 brakes. (4) remove the cotter pin, nut retainer and axle hub nut (fig. 9). (5) remove the hub mounting bolts and remove hub ...

  • Page 52

    (4) remove stud from hub with remover c-4150a (fig. 10). Installation (1) install new stud into hub flange. (2) install three washers onto stud, then install lug nut with the flat side of the nut against the washers. (3) tighten lug nut until the stud is pulled into the hub flange. Verify that the s...

  • Page 53

    Special tools front suspension remover/installer suspension bushing 7932 (j-35581) nut, long 7603 (j-21474–18) bolt, special 7604 (j-21474–19) remover c-4150a remover tie rod end mb-990635 zg suspension 2 - 13.

  • Page 54

    Rear suspension index page page description and operation rear suspension . . . . . . . . . . . . . . . . . . . . 14 diagnosis and testing shock diagnosis . . . . . . . . . . . . . . . . . . . . 15 removal and installation coil spring . . . . . . . . . . . . . . . . . . . . . . . . . 15 lower suspen...

  • Page 55

    Diagnosis and testing shock diagnosis a knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts. If the noise persists, inspect for damage...

  • Page 56

    Lower suspension arm removal (1) raise and support the vehicle. (2) remove the lower suspension arm nut and bolt at the axle bracket (fig. 3). (3) remove the nut and bolt (fig. 3) at the frame rail and remove the lower suspension arm. Installation (1) position the lower suspension arm at the axle br...

  • Page 57

    Installation (1) install the track bar to the axle bracket and install a new bolt. (2) it may be necessary to pry the axle assembly over to install the track bar. Install the track bar to the frame rail bracket. Loosely install the bolt and flag nut. (3) remove the supports and lower the vehicle. (4...

  • Page 59: Differential And Driveline

    Differential and driveline contents page page 181 fbi axle . . . . . . . . . . . . . . . . . . . . . . . . . . 15 194 rbi axle . . . . . . . . . . . . . . . . . . . . . . . . . 50 216 rba axle . . . . . . . . . . . . . . . . . . . . . . . . . 87 propeller shafts . . . . . . . . . . . . . . . . . . ....

  • Page 60

    Front propeller shaft there are two front propeller shafts used on zj vehicles. Both shafts use a double cardan joint at the transfer case end. The difference between the two shafts is how they connect to the front axle and how they handle the variation in length required by sus- pension travel. The...

  • Page 61

    Lubrication the slip yoke on the one style of front propeller shaft is equipped with a lubrication fitting. Use a multi-purpose nlgi grade 2 ep lubricant. The fac- tory installed universal joints are lubricated for the life of the vehicle and do not need lubrication. All universal joints should be i...

  • Page 62

    Also make alignment reference marks (fig. 6) on the propeller shaft yoke and axle, or transmission, yoke prior to servicing. This helps to eliminate possi- ble vibration. Caution: do not allow the propeller shaft to drop or hang from any propeller shaft joint during removal. Attach the propeller sha...

  • Page 63

    (3) inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the pro- peller shaft is bent, it must be replaced. (4) inspect the universal joints to ensure that they are not worn, are properly installed, and are cor- rectly aligned with the shaft. (5) check the unive...

  • Page 64

    Service procedures driveline angle measurement preparation before measuring universal joint angles, the fol- lowing must be done; • inflate all tires to correct pressure. • check the angles in the same loaded or unloaded condition as when the vibration occurred. Propeller shaft angles change accordi...

  • Page 65

    Removal and installation front propeller shaft 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) raise and support vehicle on safety stands. (2) shift the transmission and transfer case, if nec- essa...

  • Page 66

    (7) separate the rear universal joint from the transfer case yoke. (8) push rear of propeller shaft upward to clear transfer case yoke. (9) separate front universal joint, or cv joint, from front axle. (10) separate propeller shaft from vehicle. Installation (1) position front propeller shaft under ...

  • Page 67

    (4) set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. (5) position the yoke with the grease fitting, if equipped, pointing up. (6) place a socket with an outside diameter smaller than the upper bearing c...

  • Page 68

    (8) install the propeller shaft. Double cardan joint disassembly individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. (1) remove the propeller shaft. (2) using a soft drift, tap the outside of the bear- ing cap assembly to lo...

  • Page 69

    (7) flip assembly and repeat step 4, step 5, and step 6 to remove the opposite bearing cap. This will then allow removal of the cross centering kit assem- bly and spring (fig. 23). (8) press the remaining bearing caps out the other end of the link yoke as described above to complete the disassembly....

  • Page 70

    (6) flip the propeller shaft yoke and install the bearing cap onto the opposite trunnion. Install a snap ring (fig. 27). (7) fit the link yoke on the remaining two trun- nions and press both bearing caps into place (fig. 28). (8) install snap rings. (9) install the centering kit assembly inside the ...

  • Page 71

    (11) press the remaining two bearing caps into place and install snap rings (fig. 31). (12) tap the snap rings to allow them to seat into the grooves (fig. 32). (13) check for proper assembly. Flex the joint beyond center, it should snap over-center in both directions when correctly assembled (fig. ...

  • Page 72

    Cams is to adjust the caster angle for the alignment of the front suspension. When using the cams to adjust the pinion angle, make sure that both cams are moved equally. After the pinion angle is adjusted, the front suspension alignment should be checked to ensure that side-to-side caster angles var...

  • Page 73

    181 fbi axle index page page general information 181 fbi axle . . . . . . . . . . . . . . . . . . . . . . . . . . 15 lubricant specifications . . . . . . . . . . . . 15 description and operation standard differential . . . . . . . . . . . . . . . 16 diagnosis and testing bearing noise . . . . . . . ...

  • Page 74

    • lubricant for axles intended for heavy-duty or trailer tow use is sae 75w–140 synthetic gear lubricant. The 181 fbi axle lubricant capacity is 1.2 l (2.5 pts.). Caution: if axle is submerged in water, lubricant must be replaced immediately to avoid possible premature axle failure. Description and ...

  • Page 75

    Driving condition. These conditions are acceleration, deceleration, coast, or constant load. When road testing, accelerate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak–noise range. If the noise stops or changes greatly: • check for insu...

  • Page 76

    Front axles diagnosis condition possible causes correction 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 necessa...

  • Page 77

    Continued condition possible causes correction 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. R...

  • Page 78

    Service procedures lubricant change (1) raise and support the vehicle. (2) remove the lubricant fill hole plug from the differential housing cover. (3) remove the differential housing cover and drain the lubricant from the housing. (4) clean the housing cavity with a flushing oil, light engine oil o...

  • Page 79

    (8) install the stabilizer bar links to the axle brackets. Tighten the nut to 95 n·m (70 ft. Lbs.) torque. (9) install the drag link and tie rod to the steering knuckles. Refer to group 2, suspension, for proper procedures. (10) install the steering damper to the axle bracket and tighten the nut to ...

  • Page 80

    Installation (1) pack the bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (ep), lithium–base lubricant to aid in installation. (2) position the spider in the yoke. Insert the seals and bearings. Tap the bearing caps into the yoke bores far enough to hold the spider in positi...

  • Page 81

    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) clamp large sealing boot clamp onto axle shaft using crimper c-4975-a. Place crimping tool c-4975-a over bridge of clamp (fig. 9). (9) tight...

  • Page 82

    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) install the pinion washer and a new nut on the pinion gear. Tighten the nut only enough to remove the shaft end play. (4) rotat...

  • Page 83

    Torque wrench. Record the torque reading for instal- lation reference. (8) using a short piece of pipe and holder 6958 to hold the pinion yoke, or pinion flange, remove the pinion nut and washer. (9) use remover c-452 and wrench c-3281 to remove the pinion yoke, or flange, (fig. 16). (10) use remove...

  • Page 84

    (6) if the original pinion bearings are being used, install differential assembly and axle shafts, if 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. (7) install the...

  • Page 85

    (9) slowly tighten the nut in 6.8 n·m (5 ft. Lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (fig. 23). (10) check rotating torque with an inch pound torque wrench (fig. 23). The torque necessary to rotate t...

  • Page 86

    (8) remove hub bearing and axle shaft assembly (fig. 26), or axle shaft from axle. Avoid damaging the axle shaft oil seals in the axle housing. (9) remove the brake rotor shield from the hub bearing or knuckle (fig. 24). Installation (1) thoroughly clean the axle shaft (fig. 24) and apply a thin fil...

  • Page 87

    Fig. 28 upper ball stud remove/install removal installation fig. 29 lower ball stud remove/install special tool 6289–12 special tool 6289–4 zg differential and driveline 3 - 29 removal and installation (continued).

  • Page 88

    Knuckle installation (1) position the steering knuckle on the ball studs. (2) install and tighten the bottom retaining nut to 109 n·m (80 ft. Lbs.) torque. Install new cotter pin. (3) install and tighten the top retaining nut to 101 n·m (75 ft. Lbs.) torque. Install new cotter pin. (4) install the h...

  • Page 89

    (13) mark or tag the differential bearing cups to indicate which side of the differential they were removed from. (14) remove spreader from housing. Installation if replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Ref...

  • Page 90

    (2) remove the bearings from the differential case with puller/press c-293-pa, c-293-39 blocks, and plug sp-3289 (fig. 37). Installation if replacement differential side bearings or differ- ential case are being installed, differential side bear- ing shim requirements may change. Refer to the differ...

  • Page 91

    Removal (1) remove differential assembly from axle hous- ing. (2) mark pinion yoke, or flange, and propeller shaft for installation alignment. (3) disconnect propeller shaft from pinion yoke, or flange. Using suitable wire, tie propeller shaft to underbody. (4) using holder 6958 to hold yoke, or fla...

  • Page 92

    (11) remove the rear pinion bearing from the pin- ion with puller/press c–293-pa and adapters c–293–39 (fig. 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 rin...

  • Page 93

    Driver handle c–4171 (fig. 47). Verify cup is cor- rectly seated. (3) apply mopar t door ease, or equivalent, stick lubricant to outside surface of front pinion bearing cup. Install the bearing cup with installer d-130 and handle c–4171 (fig. 48). (4) install front pinion bearing, and oil slinger, i...

  • Page 94

    Note: if the spacer requires more than 352 n·m (260 ft. Lbs.) of torque to crush, the collapsible spacer is defective. (10) using holder 6958, a short length of 1 in. Pipe, and torque wrench (set at 352 n·m (260 ft. Lbs.)), crush collapsible spacer until bearing end play is taken up (fig. 53). (11) ...

  • Page 95

    Removal (1) remove differential from axle housing. (2) place differential case in a suitable vise with soft metal jaw protectors. (fig. 55) (3) remove bolts holding ring gear to differential case. (4) using a soft hammer, drive ring gear from dif- ferential case (fig. 55). Installation caution: do n...

  • Page 96

    (4) install the roll pin to hold the pinion mate shaft in the differential case (fig. 59). (5) install the ring gear. (6) lubricate all differential components with hypoid gear lubricant. Final assembly (1) scrape the residual sealant from the housing and cover mating surfaces. Clean the mating surf...

  • Page 97

    Wash bearings with solvent and towel dry, or dry with compressed air. Do not spin bearings with compressed air. Cup and bearing must be replaced as matched sets only. Clean axle shaft tubes and oil channels in housing. Inspect for; • smooth appearance with no broken/dented sur- faces on the bearing ...

  • Page 98

    Without any shims placed behind the rear pinion bearing cup. Take measurements with pinion gauge set 6774 and dial indicator c-3339 (fig. 63). (1) assemble pinion height block 6739, pinion block 6733, and rear pinion bearing onto screw 6741 (fig. 63). (2) insert assembled height gauge components, re...

  • Page 99

    Flush against the rearward surface of the pinion height block (fig. 63). Hold scooter block in place and zero the dial indicator face to the pointer. Tighten dial indicator face lock screw. (7) with scooter block still in position against the pinion height block, slowly slide the dial indicator prob...

  • Page 100

    Shim selection note: it is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary. (1) remove differential side bearings from differ- ential case. (2) remove factory installed shims from differen- tial case. (3) install ring gear o...

  • Page 101

    Shims to compress, or preload the new bearings when the differential is installed. (15) rotate dial indicator out of the way on the guide stud. (16) remove differential case and dummy bearings from axle housing. (17) install the pinion gear in axle housing. Install the pinion yoke, or flange, and es...

  • Page 102

    (34) rotate the differential case several times to seat the side bearings. (35) position the indicator plunger against a ring gear tooth (fig. 76). (36) push and hold ring gear upward while not allowing the pinion gear to rotate. (37) zero dial indicator face to pointer. (38) push and hold ring gear...

  • Page 103

    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 ...

  • Page 104

    181 fbi axle description torque fill hole plug . . . . . . . . . . . . . . 34 n·m (25 ft. Lbs.) diff. Cover bolt . . . . . . . . . . . . 41 n·m (30 ft. Lbs.) bearing cap bolt . . . . . . . . . . . 61 n·m (45 ft. Lbs.) ring gear bolt . . . . . . 95–122 n·m (70–90 ft. Lbs.) axle nut . . . . . . . . . ...

  • Page 105

    Driver—c-3716-a handle—c-4171 installer—d-146 remover—d-149 installer—w-162-d cup—8109 remover/installer—6289 installer—6761 zg differential and driveline 3 - 47 special tools (continued).

  • Page 106

    Installer—6752 installer discs—8110 turnbuckle—6797 tool set, pinion depth—6774 gauge block—6733 puller—7794-a installer—c-4975-a 3 - 48 differential and driveline zg special tools (continued).

  • Page 107

    Spanner—6958 installer—c-3972-a spreader—w-129-b adapter kit—6987 pilot stud—c-3288-b remover—c-4345 installer—d-130 installer—w-262 zg differential and driveline 3 - 49 special tools (continued).

  • Page 108

    194 rbi axle index page page general information 194 rbi axle . . . . . . . . . . . . . . . . . . . . . . . . . 50 lubricant specifications . . . . . . . . . . . . 50 description and operation standard differential . . . . . . . . . . . . . . . 51 trac-lok operation . . . . . . . . . . . . . . . . ....

  • Page 109

    Axle lubricant capacity is 1.66l (3.50 pts.) total, including the friction modifier if necessary. Caution: if axle is submerged in water, lubricant must be replaced immediately to avoid possible premature axle failure. Description and operation standard differential the differential gear system divi...

  • Page 110

    The trac-lok design provides the differential action needed for turning corners and for driving straight ahead during periods of unequal traction. When one wheel looses traction, the clutch packs transfer addi- tional torque to the wheel having the most traction. Trac-lok differentials resist wheel ...

  • Page 111

    Level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 mph. Low speed knock low speed knock is generally caused by a worn u–joint or by worn side–gear thrust washers. A worn pinion gear shaft bore will also cause low speed knock. Vibration vibration at the...

  • Page 112

    Condition possible causes correction 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 ...

  • Page 113

    Condition possible causes correction 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 wor...

  • Page 114

    Trac–lok test warning: when servicing vehicles with a trac–lok differential do not use the engine to turn the axle and wheels. Both rear wheels must be raised and the vehi- cle supported. A trac–lok axle can exert enough force if one wheel is in contact with a surface to cause the vehicle to move. T...

  • Page 115

    (2) position a suitable lifting device under the axle. (3) secure axle to device. (4) remove the wheels and tires. (5) remove the brake rotors and calipers from the axle. Refer to group 5, brakes, for proper procedures. (6) disconnect parking brake cables from brackets and lever. (7) remove wheel sp...

  • Page 116

    Installation (1) apply a light coating of gear lubricant on the lip of pinion seal. Install seal with installer c-3972-a and handle c–4171 (fig. 10). (2) install yoke on the pinion gear with screw 8112, cup 8109, and holder 6958 (fig. 11). Caution: do not exceed the minimum tightening torque when in...

  • Page 117

    (9) install the brake rotors and calipers. Refer to group 5, brakes, for proper procedures. (10) install wheel and tire assemblies. (11) lower the vehicle. Collapsible spacer removal w/pinion installed (1) raise and support the vehicle. (2) remove wheel and tire assemblies. (3) remove rear brake rot...

  • Page 118

    (4) mark the propeller shaft and pinion yoke for installation reference. (5) remove the propeller shaft from the yoke. (6) rotate the pinion gear three or four times. (7) measure the amount of torque necessary to rotate the pinion gear with a (in. Lbs.) dial-type torque wrench. Record the torque rea...

  • Page 119

    Caution: never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new col- lapsible spacer must be installed. The torque sequence will then have to be repeated. (9) using yoke holder 695...

  • Page 120

    (16) install wheel and tire assemblies. (17) lower vehicle. Axle shaft removal (1) raise and support vehicle. Ensure that the transmission is in neutral. (2) remove wheel and tire assembly. (3) remove brake caliper and rotor. Refer to group 5, brakes, for proper procedure. (4) clean all foreign mate...

  • Page 121

    (2) install axle shaft bearing with installer 6436 and handle c–4171. Ensure that the part number on the bearing is against the installer. (3) install the new axle shaft seal with installer 6437 and handle c–4171 (fig. 26). (4) install the axle shaft. Differential removal (1) raise and support vehic...

  • Page 122

    Caution: do not spread over 0.38 mm (0.015 in). If the housing is over–spread, it could be distorted or damaged. (9) spread the housing enough to remove the dif- ferential case from the housing. Measure the dis- tance with the dial indicator (fig. 30). (10) remove the dial indicator. (11) while hold...

  • Page 123

    And the housing. Tap the differential case to ensure the bearings cups and shims are fully seated in the housing. (6) install the bearing caps at their original loca- tions (fig. 33). (7) loosely install differential bearing cap bolts. (8) remove axle housing spreader. (9) tighten the bearing cap bo...

  • Page 124

    (1) invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (2) invert the differential case in the vise. (3) install new ring gear bolts and alternately tighten to 95–122 n·m (70–90 ft. Lbs.) torque (fig. 56). (4) install differential in ...

  • Page 125

    (5) using remover c–452 and wrench c–3281, remove the pinion yoke from pinion shaft (fig. 39). (6) remove the pinion gear from housing (fig. 40). Catch the pinion with your hand to prevent it from falling and being damaged. (7) use remover 7794-a and slide hammer to remove the pinion shaft seal (fig...

  • Page 126

    (10) remove the rear bearing cup from housing (fig. 43). Use remover d-149 and handle c–4171. (11) remove the collapsible preload spacer (fig. 44). (12) remove the rear bearing from the pinion with puller/press c-293-pa and adapters c-293-40 (fig. 45). Place 4 adapter blocks so they do not damage th...

  • Page 127

    (4) install the pinion front bearing cup with installer d–130 and handle c–4171 (fig. 47). (5) install pinion front bearing, and oil slinger, if equipped. (6) apply a light coating of gear lubricant on the lip of pinion seal. Install seal with installer c-3972-a and handle c–4171 (fig. 48). Note: pi...

  • Page 128

    Caution: never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new col- lapsible spacer must be installed. The torque sequence will then have to be repeated. (14) using yoke holder 69...

  • Page 129

    Disassembly and assembly standard differential disassembly (1) remove pinion gear mate shaft lock screw (fig. 55). (2) remove pinion gear mate shaft. (3) rotate the differential side gears and remove the pinion mate gears and thrust washers (fig. 56). (4) remove the differential side gears and thrus...

  • Page 130

    Trac-lok differential the trac–lok differential components are illustrated in (fig. 57). Refer to this illustration during repair service. Disassembly (1) clamp side gear holding tool 6965 in a vise. (2) position the differential case on side gear holding tool 6965 (fig. 58). (3) remove ring gear, i...

  • Page 131

    (8) position a small screw driver in slot of threaded adapter c-6960-1 (fig. 62) to prevent adapter from turning. (9) tighten forcing screw tool 122 n·m (90 ft. Lbs.) maximum to compress belleville springs in clutch packs (fig. 63). (10) using an appropriate size feeler gauge, remove thrust washers ...

  • Page 132

    Lubricate each component with gear lubricant before assembly. (1) assemble the clutch discs into packs and secure disc packs with retaining clips (fig. 67). (2) position assembled clutch disc packs on the side gear hubs. (3) install clutch pack and side gear in the ring gear side of the differential...

  • Page 133

    Tighten the forcing screw in order to install the pin- ion gears. (12) tighten forcing screw to 122 n·m (90 ft. Lbs.) maximum to compress the belleville springs. (13) lubricate and install thrust washers behind pinion gears and align washers with a small screw driver. Insert mate shaft into each pin...

  • Page 134

    Presoak plates and disc plates and discs with fiber coating (no grooves or lines) must be presoaked in friction modifier before assembly. Soak plates and discs for a minimum of 20 minutes. Adjustments pinion gear depth general information ring and pinion gears are supplied as matched sets only. The ...

  • Page 135

    Tor face to the pointer. Tighten dial indicator face lock screw. (7) with scooter block still in position against the pinion height block, slowly slide the dial indicator probe over the edge of the pinion height block. Observe how many revolutions counterclockwise the dial pointer travels (approxima...

  • Page 136

    Ple, if the depth variance is –2, add +0.002 in. To the dial indicator reading. (10) remove the pinion depth gauge components from the axle housing differential bearing preload and gear backlash differential side bearing preload and gear backlash is achieved by selective shims inserted between the b...

  • Page 137

    (13) add the dial indicator reading to the starting point shim thickness to determine total shim thick- ness to achieve zero differential end play. (14) add 0.008 in. (0.2 mm) to the zero end play total. This new total represents the thickness of shims to compress, or preload the new bearings when t...

  • Page 138

    After the proper backlash is achieved, perform the gear contact pattern analysis procedure. Gear contact pattern analysis the ring and pinion gear teeth contact patterns will show if the pinion gear depth is correct in the axle housing. It will also show if the ring gear back- lash has been adjusted...

  • Page 139

    Fig. 81 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 ...

  • Page 140

    Specifications 194 rbi axle description specification axle type . . . . . . . . . . . . . . . Semi–floating hypoid lubricant . . . . . . . . Sae thermally stable 80w–90 lubricant trailer tow . . . . . . . . Synthetic 75w–140 lube capacity . . . . . . . . . . . . . . . . 1.66 l (3.50 pts.) axle ratio...

  • Page 141

    Wrench—c-3281 installer—c-3972-a spanner—6958 installer screw—8112 cup—8109 handle—c-4171 driver—c-3716-a installer—d-130 zg differential and driveline 3 - 83 special tools (continued).

  • Page 142

    Installer—d-146 remover—c-4345 remover—d-149 installer—w-262 installer—6436 installer—6437 disc, axle arbor—6732 gauge block—6735 3 - 84 differential and driveline zg special tools (continued).

  • Page 143

    Tool set, pinion depth—6774 trac-lok tool set—6960 holder—6965 puller—7794-a starting point shim—8107 spreader—w-129-b adapter kit—6987 guide pin—c-3288-b zg differential and driveline 3 - 85 special tools (continued).

  • Page 144

    Bearing remover tool set—6310 hub puller—6790 dial indicator—c-3339 3 - 86 differential and driveline zg special tools (continued).

  • Page 145

    216 rba axle index page page general information 216 rba axle . . . . . . . . . . . . . . . . . . . . . . . . . 87 lubricant specifications . . . . . . . . . . . . 87 description and operation standard differential . . . . . . . . . . . . . . . 88 trac-lok operation . . . . . . . . . . . . . . . . ....

  • Page 146

    Rba axle lubricant capacity is 2.25 l (4.75 pts.) total, including the friction modifier if necessary. Caution: if axle is submerged in water, lubricant must be replaced immediately to avoid possible premature axle failure. Description and operation standard differential the differential gear system...

  • Page 147

    The trac-lok design provides the differential action needed for turning corners and for driving straight ahead during periods of unequal traction. When one wheel looses traction, the clutch packs transfer addi- tional torque to the wheel having the most traction. Trac-lok differentials resist wheel ...

  • Page 148

    Level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 mph. Low speed knock low speed knock is generally caused by a worn u–joint or by worn side–gear thrust washers. A worn pinion gear shaft bore will also cause low speed knock. Vibration vibration at the...

  • Page 149

    Condition possible causes correction 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 ...

  • Page 150

    Condition possible causes correction 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 wor...

  • Page 151

    Trac–lok test warning: when servicing vehicles with a trac–lok differential do not use the engine to turn the axle and wheels. Both rear wheels must be raised and the vehi- cle supported. A trac–lok axle can exert enough force if one wheel is in contact with a surface to cause the vehicle to move. T...

  • Page 152

    (2) position a suitable lifting device under the axle. (3) secure axle to device. (4) remove the wheels and tires. (5) remove the brake rotors and calipers from the axle. Refer to group 5, brakes, for proper procedures. (6) disconnect parking brake cables from brackets and lever. (7) remove wheel sp...

  • Page 153

    Installation (1) apply a light coating of gear lubricant on the lip of pinion seal. Install seal with installer c-3972-a and handle c-4171 (fig. 10). (2) install yoke on the pinion gear with installer c-3718 and holder 6958 (fig. 11). Caution: do not exceed the minimum tightening torque when install...

  • Page 154

    (5) if the rotating torque is low, use holder 6958 to hold the pinion yoke (fig. 13), and tighten the pinion shaft nut in 6.8 n·m (5 ft. Lbs.) increments until proper rotating torque is achieved. Caution: if the maximum tightening torque is reached prior to reaching the required rotating torque, the...

  • Page 155

    (9) using holder 6958 to hold yoke and a short length of 1 in. Pipe, remove the pinion yoke nut and washer (fig. 14). (10) using remover c–452 and wrench c–3281, remove the pinion yoke from pinion shaft (fig. 15). (11) remove the pinion gear from housing (fig. 17). Catch the pinion with your hand to...

  • Page 156

    (7) install the yoke washer and a new nut on the pinion gear. Tighten the nut to 298 n·m (220 ft. Lbs.) minimum. Do not over–tighten. Maximum torque is 380 n·m (280 ft. Lbs.). Caution: never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload tor...

  • Page 157

    (6) rotate differential case so that pinion mate gear shaft lock screw is accessible. Remove lock screw and pinion mate gear shaft from differential case (fig. 23). (7) push axle shaft inward and remove axle shaft c–clip lock from the axle shaft (fig. 24). (8) remove axle shaft. Use care to prevent ...

  • Page 158

    (4) inspect the axle 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) wipe the bore in the axle shaft tube clean. (2) install axle shaft bearing with installer 6436 and handle c–4171. Ensure part nu...

  • Page 159

    Against the opposite side of the housing (fig. 28) and zero the indicator. (3) spread the housing enough to install the case in the housing. Measure the distance with the dial indicator (fig. 28). Caution: do not spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or...

  • Page 160

    Installation caution: do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. (1) invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. (2) invert the differential case in...

  • Page 161

    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 (1) remove differential assembly from axle hous- ing. (2) mark pinion yoke and propeller shaft for installation alignment. (3) disconnect propeller shaft ...

  • Page 162

    (12) remove the rear bearing from the pinion with puller/press c-293-pa and adapters c-293-42 (fig. 42). Place 4 adapter blocks so they do not damage the bearing cage. (13) remove the pinion depth shims from the pin- ion gear shaft. Record the total thickness of the depth shims. Installation (1) app...

  • Page 163

    (3) install pinion front bearing and oil slinger, if equipped. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with installer c-3972-a and handle c-4171 (fig. 45). Note: pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve prop...

  • Page 164

    Caution: never loosen pinion gear nut to decrease pinion gear bearing preload torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed. The torque sequence will have to be repeated. Note: if the spacer requires more than 280 ft. Lbs. ...

  • Page 165

    Disassembly and assembly standard differential disassembly (1) remove pinion gear mate shaft lock screw (fig. 55). (2) remove pinion gear mate shaft. (3) rotate the differential side gears and remove the pinion mate gears and thrust washers (fig. 56). (4) remove the differential side gears and thrus...

  • Page 166

    (7) assemble threaded adapter c–4487–3 into top side gear. Thread forcing screw c–4487–2 into adapter until it becomes centered in adapter plate. (8) position a small screw driver in slot of threaded adapter c–4487–3 (fig. 59) to prevent adapter from turning. (9) tighten forcing screw tool 122 n·m (...

  • Page 167

    (13) rotate differential case until the pinion gears can be removed. (14) remove pinion gears from differential case. (15) remove forcing screw c–4487-2, step plate c-4487-1, and threaded adapter c-4487-3. (16) remove top side gear, clutch pack retainer, and clutch pack. Keep plates in correct order...

  • Page 168

    (4) position the differential case on side gear holding tool 6963-a. (5) install lubricated step plate c–4487–1 on side gear (fig. 66). (6) install the upper side gear and clutch disc pack (fig. 66). (7) hold assembly in position. Insert threaded adapter c–4487–3 into top side gear. (8) insert forci...

  • Page 169

    (15) install pinion gear mate shaft and align holes in shaft and case. (16) install the pinion mate shaft lock screw finger tight to hold shaft during differential installation. If replacement side and/or pinion gears and thrust washers were installed, it is not neces- sary to measure the side gear ...

  • Page 170

    Pinion gear are etched into the face of each gear (fig. 67). A plus (+) number, minus (–) number or zero (0) is etched into the face of the pinion gear. This num- ber is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion etched with a (0). The standar...

  • Page 171

    Pointer back to zero against the arbor bar, do not turn dial face. Continue moving the dial probe to the crest of the arbor bar and record the highest reading. If the dial indicator can not achieve the zero reading, the rear bearing cup or the pinion depth gauge set is not installed correctly. (9) s...

  • Page 172

    Lash measurements, measure the pinion gear depth and prepare the pinion gear for installation. Estab- lishing proper pinion gear depth is essential to estab- lishing gear backlash and tooth contact patterns. After the overall shim thickness to take up differen- tial side play is measured, the pinion...

  • Page 173

    (6) install the marked bearing caps in their correct positions. Install and snug the bolts. (7) thread guide stud c-3288-b into rear cover bolt hole below ring gear (fig. 75). (8) attach dial indicator c-3339 to guide stud c-3288-b. Position the dial indicator plunger on a flat surface between the r...

  • Page 174

    Adjusted within specifications to achieve desired tooth contact patterns. (1) apply a thin coat of hydrated ferric oxide, or equivalent, to the drive and coast side of the ring gear teeth. (2) wrap, twist, and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion ...

  • Page 175

    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 ...

  • Page 176

    Specifications 216 rba axle description spec. Type . . . . . . . . . . . . . . . . . . . . Semi-floating hypoid axle ratios . . . . . . . . . . . . . . . . . . . . . . . . 3.55/3.73 ring gear diameter . . . . . . . . . . 216 mm (8.5 in.) gear backlash . . . 0.13–0.20 mm (0.005–0.008 in.) pinion dept...

  • Page 177

    Holder—c-3281 installer—c-3718 handle—c-4171 remover—c-4307 installer—c-4308 installer—c-4340 guide pin—c-3288-b dial indicator—c-3339 zg differential and driveline 3 - 119 special tools (continued).

  • Page 178

    Trac-lok tool set—c-4487 installer—c-3972-a installer—d-129 remover—d-103 spreader—w-129-b remover—6310 installer—6436 installer—6437 3 - 120 differential and driveline zg special tools (continued).

  • Page 179

    Installer—6448 adapter—6790 pinion depth set—6955 adapter set—6956 gauge block—8144 starting point shim—8107 holder—6958 holder—6963-a remover—7794-a zg differential and driveline 3 - 121 special tools (continued).

  • Page 181: Brakes

    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 . . . . ...

  • Page 182

    General information brake system all vehicles are equipped with power assist four- wheel disc brakes. Antilock (abs) brakes are also standard equipment on all models. Single piston, disc brake calipers are used front and rear. Ventilated disc brake rotors are used at the front and solid rotors are u...

  • Page 183

    Through a hose attached to an intake manifold fitting at one end and to the booster check valve at the other. The vacuum check valve in the booster housing is a one-way device that prevents vacuum leak back. Power assist is generated by utilizing the pressure differential between normal atmospheric ...

  • Page 184

    Parking brake shoes (fig. 5). Parking brake shoe ser- vice is covered in the parking brake service section. The outboard shoe now has an anti-rattle spring attached at the shoe rear. A wear strip is mounted to the inboard shoe. Parking brakes the parking brakes are operated by a cable and hand lever...

  • Page 185

    Brake hoses and lines flexible rubber hose is used at both front brakes and at the rear axle junction block. Double walled steel tubing is used to connect the master cylinder to the major hydraulic braking components and then to the flexible rubber hoses. Diagnosis and testing base brake system base...

  • Page 186

    Separated into layers, or contains a substance other than brake fluid. The system seals and cups will also have to be replaced after flushing. Use clean brake fluid to flush the system. (4) check parking brake operation. Verify free movement and full release of cables and pedal. Also note if vehicle...

  • Page 187

    Mountain roads. Refer to the brake drag information in this section for causes. Brake pull front brake pull condition could result from: • contaminated lining in one caliper • seized caliper piston • binding caliper • loose caliper • rusty adapter/caliper slide surfaces • improper brake shoes • dama...

  • Page 188

    Switch circuit identification • terminals 1 and 2 are for brake sensor circuit. • terminals 5 and 6 are for the stop lamp circuit. • terminals 3 and 4 are for the speed control cir- cuit. Switch continuity test (1) check continuity between terminal pins 5 and 6 as follows: (a) pull plunger all the w...

  • Page 189

    Faulty, replace the entire combination valve as an assembly. Pressure differential switch (1) have helper sit in drivers seat to apply brake pedal and observe red brake warning light. (2) raise vehicle on hoist. (3) connect bleed hose to a rear wheel cylinder and immerse hose end in container partia...

  • Page 190

    Rotor with the wheel nuts and 4 or 5 large diameter flat washers on each stud. Use a dial indicator to check lateral runout (fig. 10). Maximum allowable rotor lateral runout is 0.13 mm (0.005 in.). Rear disc brake rotor rotor minimum thickness minimum usable thickness of the rear disc brake rotor is...

  • Page 191

    The result of worn brake shoes, improper brake shoe adjustment, or improperly assembled brake parts. A “too loose” condition can also be caused by inop- erative or improperly assembled parking brake shoe parts. A condition where the parking brakes do not hold, will most probably be due to a wheel br...

  • Page 192

    Note: if master cylinders has one reservoir open- ing, position both bleed tubes into the single reser- voir opening (fig. 14). (3) fill reservoir with fresh brake fluid. (4) press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue ...

  • Page 193

    Stem must either be pressed inward, or held outward slightly. A spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Gen- erally, a tank p...

  • Page 194

    (9) tighten tool handle until plug gauge is seated on jaws of flaring tool. This will start the inverted flare. (10) remove the plug gauge and complete the inverted flare. (11) remove the flaring tools and verify that the inverted flare is correct. Removal and installation stop lamp switch removal (...

  • Page 195

    (9) check and adjust brakelamp switch if neces- sary. Combination valve removal (1) remove brake lines that connect master cylin- der to combination valve (fig. 21). (2) disconnect brake lines that connect combina- tion valve to hcu. (3) disconnect wire from combination valve switch terminal. Be car...

  • Page 196

    Installation (1) remove protective cover from end of primary piston. (2) bleed master cylinder. (3) slide master cylinder onto booster studs. Align booster push rod in cylinder primary piston and seat cylinder against booster. (4) install master cylinder mounting nuts and tighten nuts to 18 n·m (155...

  • Page 197

    (4) rotate caliper rearward with pry tool if neces- sary. Then rotate caliper and brake shoes off mount- ing ledges. (5) remove caliper from vehicle. Installation (1) install brake shoes in caliper. (2) connect brake hose to caliper but do not tighten fitting bolt completely at this time. Be sure to...

  • Page 198

    (6) remove outboard shoe by pressing one end of shoe inward to disengage shoe lug. Then rotate shoe upward until retainer spring clears caliper. Press opposite end of shoe inward to disengage shoe lug and rotate shoe up and out of caliper (fig. 30). (7) remove inboard shoe. Grasp ends of shoe and ti...

  • Page 199

    (5) install and tighten caliper mounting bolts to 10-20 n·m (7-15 ft. Lbs.). 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 inbo...

  • Page 200

    (2) position caliper over rotor and into bracket. Be sure brake shoe tabs are properly seated on mount- ing bracket ledges. (3) connect rear brake hose to caliper. Use new washers on hose fitting and tighten hose fitting bolt to 24-38 n·m (216-336 in. Lbs.). (4) check brake hose position before proc...

  • Page 201

    Installation (1) clean brake shoe contact surfaces of caliper mounting bracket (fig. 40). Use wire brush or emery cloth. (2) install brake shoes in caliper. (3) install caliper over rotor and into mounting bracket. (4) verify that brake shoe lugs are properly seated on caliper mounting bracket (fig....

  • Page 202

    Parking brake hand lever removal (1) release parking brakes. (2) disconnect battery negative cable. (3) raise vehicle on hoist. (4) remove front cable adjusting nut and disen- gage cable tensioner from equalizer. Then remove front cable from tensioner (fig. 43). (5) disengage front cable from insert...

  • Page 203

    Installation (1) connect front cable to lever assembly. (2) seat front cable in floor pan. (3) install lever assembly. (4) install console. (5) raise vehicle. (6) assemble front cable, cable tensioner and equalizer. (7) adjust parking brake system if new cable, or tensioner has been installed, or if...

  • Page 204

    On shoes and that star wheel is aligned with access hole in shield. (4) install shoe upper and lower return spring. Needle nose pliers can be used to connect spring to each shoe. Operate lever to verify that shoes expand and retract properly. (5) install rotor and caliper. (6) adjust parking brake s...

  • Page 205

    (2) engage cam in lever. Then simultaneously slide cam into place on splash shield and work lever through boot (fig. 52). (3) install parking brake shoes. (4) verify correct installation of cam and lever by pulling lever toward front of vehicle. Cam should expand both brake shoes as lever is pulled ...

  • Page 206

    (2) apply thin coat of contact cement or silicone adhesive to new lever boot and to boot mounting area of caliper bracket (fig. 55). Apply adhesive to areas where boot and bracket contact one another. Adhe- sive is needed to hold boot in position when splash shield is attached to bracket. (3) instal...

  • Page 207

    (11) lower vehicle and verify correct service and parking brake operation. Disassembly and assembly master cylinder reservoir removal (1) remove reservoir cap and empty fluid into drain container. (2) remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove pins (fig....

  • Page 208

    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) lubricate new grommets with clean brake fluid and install new grommets in cylinder body (fig...

  • Page 209

    (5) remove caliper piston dust boot with suitable tool (fig. 67) and discard boot. (6) remove caliper piston seal with wood or plastic tool (fig. 68) and discard seal. Do not use metal tools as they will scratch piston bore. (7) remove caliper mounting bolt bushings and boots (fig. 69). Assembly (1)...

  • Page 210

    (5) install dust boot on caliper piston and seat boot in piston groove (fig. 72). (6) press piston into caliper bore by hand, use a turn and push motion to work piston into seal (fig. 73). (7) press caliper piston to bottom of bore. (8) seat dust boot in caliper with installer tool c-4842 and tool h...

  • Page 211

    Assembly (1) lubricate caliper piston bore and new piston seal with clean brake fluid. (2) install new piston seal in groove machined in piston bore. Be sure seal is fully seated and is not twisted. Press seal into place with fingertips. (3) lubricate caliper piston with clean brake fluid and start ...

  • Page 212

    (7) press caliper to bottom of bore after seating dust boot. Be sure to use wood block to protect piston and boot. (8) install caliper bleed screw, if removed. (9) install bushing and boot assemblies in caliper. Be sure boots are centered in caliper as shown. (10) apply silicone grease to interior o...

  • Page 213

    (6) reinstall brake drums and wheel/tire assem- blies after brake shoe adjustment is complete. (7) lower vehicle enough for access to parking brake lever. Then fully apply parking brakes. Leave brakes applied until adjustment is complete. (8) raise vehicle and mark tensioner rod 6.5 mm (1/4 in.) fro...

  • Page 214

    Front disc brake caliper brake booster type . . . . . . . . . . . . . . . . . . . . . . Dual diaphragm torque chart description torque brake pedal support bolt . . . . . . . . . 23-34 n·m (17-25 ft. Lbs.) pivot bolt/nut . . . . . . . . 27-35 n·m (20-26 ft. Lbs.) brake booster mounting nuts . . . . ....

  • Page 215

    Antilock brakes index page page general information antilock brake system . . . . . . . . . . . . . . 35 description and operation abs system relays . . . . . . . . . . . . . . . . . . 38 abs warning lamp . . . . . . . . . . . . . . . . . . . 38 acceleration switch . . . . . . . . . . . . . . . . 38...

  • Page 216

    The cab will not activate any abs components as long as sensor inputs and the acceleration switch indicate normal braking. During normal braking, the master cylinder, power booster and wheel brake units all function as they would in a vehicle without abs. The hcu compo- nents are not activated. Anti...

  • Page 217

    A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the cab closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed t...

  • Page 218

    Acceleration switch the acceleration switch is located under the rear seat. The switch (fig. 4), provides an additional vehi- cle deceleration reference during 4wd operation. The switch is monitored by the cab at all times. The switch reference signal is utilized by the cab when all wheels are decel...

  • Page 219

    (3) install the brake lines to the hcu and tighten to 16 n·m (12 ft. Lbs.). (4) install cab harness connector and push-in connector release. (5) install steering gear shield. (6) install windshield reservoir and mounting bolts. (7) install air cleaner housing. (8) install negative battery cable to t...

  • Page 220

    (8) remove sensor and wire assembly. Installation (1) apply mopar lock n’ seal or loctite 242 to sensor attaching bolt. Use new sensor bolt if original bolt is worn or damaged. (2) position sensor on steering knuckle. Seat sen- sor locating tab in hole in knuckle and install sensor attaching bolt fi...

  • Page 221

    (3) tilt rear seat assembly forward for access to the switch. (4) disconnect switch harness (fig. 12). (5) remove bolts attaching switch to bracket and remove the switch. Installation caution: the mercury switch inside the accelera- tion switch, will only function properly if the locat- ing arrow is...

  • Page 222

    Assembly (1) install the cab onto the hcu. (2) install the cab mounting screws and tighten to 1.8 n·m (16 in. Lbs.). (3) install pump motor connector to the cab. Specifications torque chart description torque acceleration sensor sensor bolt . . . . . . . . . . . . 8-9 n·m (71-83 in. Lbs.) bracket bo...

  • Page 223: Clutch

    Clutch contents page page general information clutch components . . . . . . . . . . . . . . . . . . 1 clutch hydraulic system . . . . . . . . . . . . . 1 removal and installation clutch cover and disc . . . . . . . . . . . . . . . . 1 flywheel ring gear . . . . . . . . . . . . . . . . . . . 5 flywhe...

  • Page 224

    Installation (1) lightly scuff sand flywheel face with 180 grit emery cloth. Then clean surface with brake or carbu- retor cleaner. (2) lightly lubricate pilot bearing with mopar t high temperature bearing grease. (3) check free operation of clutch disc by sliding disc onto transmission output shaft...

  • Page 225

    Pilot bearing removal (1) remove transmission and transfer case. (refer to group 21, transmissions and transfer case.) (2) remove clutch cover and disc. (3) remove the four bolts that attach the pilot bearing retainer to the flywheel (fig. 4). (4) remove the pilot bearing retainer. (5) support the b...

  • Page 226

    Edge of chamfer in retainer bore (fig. 7). Reposition bearing if necessary. (2) install bearing retainer and tighten bolts. (3) lubricate pilot bearing with mopar t high tem- perature wheel bearing grease. (4) lightly scuff sand flywheel surface with 180 grit emery cloth. Clean the surface with mopa...

  • Page 227

    (4) install and tighten new flywheel bolts as fol- lows: (a) lubricate bolt threads with engine oil. (b) install and tighten bolts to initial torque of 20 n·m. Tighten bolts diagonally in pairs (fig. 10). (c) tighten each bolt and additional 60° turn. Continue tightening bolts in small increments to...

  • Page 229: Cooling System

    Cooling system contents page page general information coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 cooling system components . . . . . . . . . . 2 cooling system . . . . . . . . . . . . . . . . . . . . . . 1 engine accessory drive belts . . . . . . . . . 1 radiator . . . . . ....

  • Page 230

    An optional factory installed maximum duty cool- ing package is available on most models. This pack- age will provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient temperatures. Cooling system components the cooling system consists of: ...

  • Page 231

    Water pump bypass hose—5.2/5.9l v-8 engines a water pump bypass hose (fig. 3) is used between the intake manifold and water pump on all 5.2/5.9l v-8 engines. Coolant the cooling system is designed around the coolant. Coolant flows through the engine water jackets absorbing heat produced during engin...

  • Page 232

    Accessory drive belt tension correct drive belt tension is required to ensure optimum performance of the belt driven engine acces- sories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capac- ity, reduced ...

  • Page 233

    The more common type of thermostat failure, usu- ally found on high mileage vehicles, is a thermostat failed in the shut position. The temperature gauge (if equipped) will give an indication of this condition. Depending upon length of time that vehicle is oper- ated, pressure cap may vent. This will...

  • Page 234

    This causes the vacuum valve to open and coolant in reserve/overflow tank to be drawn through connect- ing hose into radiator. If the vacuum valve is stuck shut, radiator hoses will collapse on cool-down. A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant ...

  • Page 235

    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. Inspect the hoses at regular intervals. Replace hoses that are cracked, feel brittle when squeezed, or swell ...

  • Page 236

    Reacts and the fan speed is reduced to the previous disengaged 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...

  • Page 237

    If the problem is sensed in a monitored circuit often enough to indicate an actual problem, a dtc is stored. The dtc will be stored in the pcm memory for eventual display to the service technician. If the problem is repaired or ceases to exist, the pcm can- cels the dtc after 51 engine starts. Certa...

  • Page 238

    Inspecting for inlet restrictions inadequate heater performance may be caused by a metal casting restriction in the water pump heater hose inlet. Do not waste reusable coolant. If solution is clean, drain the coolant into a clean container for reuse. Warning: do not loosen the radiator draincock wit...

  • Page 239

    Serpentine drive belt diagnosis–4.0l 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...

  • Page 240

    Serpentine drive belt diagnosis-5.2/5.9l 8-cylinder engines condition possible causes correction 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...

  • Page 241

    Preliminary checks engine cooling system overheating establish what driving conditions caused the com- plaint. Abnormal loads on the cooling system such as the following may be the cause. (1) prolonged idle, very high ambient temperature, slight tail wind at idle, slow traffic, traffic jams, high sp...

  • Page 242

    Cooling system diagnosis condition possible causes correction 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...

  • Page 243

    Condition possible causes correction 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 ...

  • Page 244

    Condition possible causes correction 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 a...

  • Page 245

    Condition possible causes correction 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 previou...

  • Page 246

    Radiator coolant flow check the following procedure will determine if coolant is flowing through the cooling system. If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper radiator hose. If hose is hot, the thermostat is open and water is circulating throug...

  • Page 247

    Leakage. If no leaks are visible, inspect for internal leakage. Large radiator leak holes should be repaired by a reputable radiator repair shop. Internal leakage inspection remove the oil pan drain plug and drain a small amount of engine oil. Coolant, being heavier, will drain first, or operate eng...

  • Page 248

    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 engine and operate at 2400 rpm. Within ten minutes the air temperature (indicated on the dial thermom...

  • Page 249

    Low coolant level-aeration if the coolant level in radiator drops below top of radiator core tubes, air will enter cooling system. Low coolant level can cause thermostat pellet to be suspended in air instead of coolant. This will cause thermostat to open later, which in turn causes higher coolant te...

  • Page 250

    (1) with engine cold, slowly remove the radiator cap. Raise vehicle on a hoist and locate radiator draincock. • 4.0l engine: radiator draincock is located on the right/lower side of radiator facing to rear of vehi- cle. • 5.2/5.9l engines: radiator draincock is located on the left/lower side of radi...

  • Page 251

    Cooling tube passages. For more information, refer to operating instructions supplied with flushing equip- ment. Have radiator cleaned more extensively by a radiator repair shop. Reverse flushing engine drain the cooling system. Remove the thermostat housing and thermostat. Install the thermostat ho...

  • Page 252

    Installation (1) position cooler to vehicle. (2) install lower hose and hose clamp to cooler. Hose clamp screws must be facing towards rear of vehicle. Tighten clamp to 2 n·m (18 in. Lbs.) torque. (3) install upper hose and hose clamp at cooler. Hose clamp screws must be facing towards rear of vehic...

  • Page 253

    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. 29) snap-on clamp tool (number hpc-20) may be used for larger clamps. Always wear safety ...

  • Page 254

    (12) remove the four pump mounting bolts (fig. 31) and remove pump from vehicle. Discard old gas- ket. Note that one of the four bolts is longer than the other bolts. (13) if pump is to be replaced, the heater hose fit- ting must be removed. Note position of fitting before removal. Installation (1) ...

  • Page 255

    Any of these conditions are found. Also check condi- tion of the thermal viscous fan drive. Refer to viscous fan drive in this group. The water pump can be removed without discharg- ing the air conditioning system (if equipped). Removal (1) disconnect negative battery cable from battery. (2) drain c...

  • Page 256

    (11) remove lower radiator hose clamp and remove lower hose at water pump. (12) remove heater hose clamp (fig. 35) and heater hose from heater hose coolant return tube. (13) loosen heater hose coolant return tube mounting bolt and nut (fig. 35) and remove tube from water pump. Discard the old tube o...

  • Page 257

    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 be...

  • Page 258

    Installation (1) install the replacement thermostat so that the pellet, which is encircled by a coil spring, faces the engine. All thermostats are marked on the outer flange to indicate the proper installed position. (a) observe the recess groove in the engine cyl- inder head (fig. 39). (b) position...

  • Page 259

    (d) remove belt from vehicle. (e) remove two generator mounting bolts. Do not remove any wiring at generator. If equipped with 4wd, unplug 4wd indicator lamp wiring har- ness (located near rear of generator). (f) remove generator. Position generator to gain access for thermostat gasket removal. (5) ...

  • Page 260

    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. 44) for correct 5.2/5.9l engine belt routing. Or, refer to the belt routing label located in the engine compartment...

  • Page 261

    (4) 4.0l engine: remove the four fan hub-to-wa- ter pump pulley mounting nuts (fig. 48). Carefully remove the fan assembly from the water pump pulley and position to center of fan shroud. Fan belt removal is not necessary as the water pump studs will hold the pump pulley in position. (5) do not remo...

  • Page 262

    From the radiator. Refer to group 21 for transmission cooling line removal and installation. (11) the radiator upper crossmember (fig. 51) can be adjusted left or right through the use of slotted holes. Before removal, mark the original position of the crossmember. (12) eight clips are used to retai...

  • Page 263

    Support bracket to lower frame crossmember (fig. 50). (17) remove the remaining four bolts securing the radiator upper crossmember to the body. Do not remove the hood latch or hood latch cable from the crossmember. Lift the crossmember straight up and lay to the side. (18) equipped with air conditio...

  • Page 264

    (3) connect the lower radiator hose and hose clamp to radiator. Caution: the tangs on the hose clamp must be positioned straight down. (4) 4.0l engine: connect the lower radiator hose at the water pump. (5) connect the upper radiator hose at the radia- tor. (6) equipped with air conditioning: instal...

  • Page 265

    (3) secure both hose clamps (fig. 53). (4) fill cooling system. Refer to refilling the cool- ing system in this group. (5) start and warm the engine. Check for leaks. With air conditioning removal if equipped with a/c, the generator and a/c com- pressor along with their common mounting bracket (fig....

  • Page 266

    (fig. 57). When all belt tension has been relaxed, remove accessory drive belt. (9) the drive belt idler pulley must be removed to gain access to one of a/c compressor/generator bracket mounting bolts. Remove idler pulley bolt and remove idler pulley (fig. 55). (10) remove oil dipstick tube mounting...

  • Page 267

    (2) drain coolant from radiator. Refer to draining cooling system in this group. (3) raise vehicle. (4) remove engine cylinder block drain plug(s) located on the sides of cylinder block above the oil pan rail (fig. 59) (fig. 60). (5) remove power cord from block heater (fig. 61) (fig. 62). (6) loose...

  • Page 268

    4.0l engine removal belt tension is adjusted at the power steering pump bracket and idler pulley assembly. (1) disconnect negative battery cable from battery. (2) loosen belt tension at power steering pump bracket and idler pulley (fig. 63). (3) remove belt. Installation (1) check condition of all p...

  • Page 269

    Installation caution: when installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (fig. 66) for correct engine belt routing. The correct belt with correct length must be used. (1) position dri...

  • Page 270

    (2) install tensioner assembly to mounting bracket. An indexing tab is located on back of ten- sioner. Align this tab to slot in mounting bracket. Tighten nut to 67 n·m (50 ft. Lbs.) torque. (3) connect all wiring to ignition coil. (4) install coil to coil bracket. If nuts and bolts are used to secu...

  • Page 271

    (5) after removing fan blade/fan drive assembly do not place the thermal viscous fan drive in the hori- zontal position. If stored horizontally, the silicone fluid in the viscous fan drive could drain into the bearing assembly and contaminate the lubricant. Installation (1) assemble fan blades to vi...

  • Page 272

    Cleaning and inspection radiator cap inspection visually inspect the pressure valve gasket on the cap. Replace cap if the gasket is swollen, torn or worn. Inspect the area around radiator filler neck for white deposits that indicate a leaking cap. Radiator cleaning the radiator and air conditioning ...

  • Page 273

    Torque specifications description torque automatic belt tensioner to mounting bracket (5.2/5.9l) bolts . . . . . . . . . . . . . . . . . . . . . . 67 n·m (50 ft. Lbs.) automatic belt tensioner to block (5.2/5.9l) bolts . . . . . . . . . . . . . . . . . . . . . . 41 n·m (30 ft. Lbs.) automatic belt t...

  • Page 275: Cooling System

    Cooling system contents page page general information cooling system . . . . . . . . . . . . . . . . . . . . . . 1 radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 engine accessory drive belts . . . . . . . . . 2 coolant tank . . . . . . . . . . . . . . . . . . . . . . . . 2 wate...

  • Page 276

    Caution: plastic tanks, while stronger than brass, are subject to damage by impact, such as wrenches. If the plastic tank has been damaged, the tank and/or gaskets are available for service repair. Tank replacement should be done by qualified personal with proper equipment. Engine accessory drive be...

  • Page 277

    Normal operating temperature. The coolant tank is equipped with a cam type pressure/vent cap. Refer to pressure/vent cap for additional information. A separate coolant reserve/overflow tank is not used with this system. The low coolant level sensor is located on the bot- tom of the tank (fig. 2). Wa...

  • Page 278

    A quick test to determine if the pump is working is to check if the heater warms properly. A defective water pump will not be able to circulate heated cool- ant through the long heater hose to the heater core. Coolant the cooling system is designed around the coolant. Coolant flows through the engin...

  • Page 279

    Propylene-glycol formulations—should not be used in chrysler vehicles propylene-glycol formulations do not meet chrysler coolant specifications. It’s overall effec- tive temperature range is smaller than that of ethyl- ene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg. C (-...

  • Page 280

    Ordinary worm gear type hose clamps (when equipped) can be removed with a straight screw- driver or a hex socket. To prevent damage to hoses or clamps, the hose clamps should be tightened to 4 n·m (34 in. Lbs.) torque. Do not over tighten hose clamps. When performing a hose inspection, inspect the r...

  • Page 281

    Automatic belt tensioner drive belt tension is controlled by a spring loaded automatic belt tensioner located below and to the front of the engine oil filter (fig. 7). This tensioner is connected to a pivot bracket and a pulley (fig. 7). The pivot bracket rotates on a pivot pin attached to the engin...

  • Page 282

    Cooling system diagnosis–diesel engine 7 - 8 cooling system zg diagnosis and testing (continued).

  • Page 283

    Zg cooling system 7 - 9 diagnosis and testing (continued).

  • Page 284

    7 - 10 cooling system zg diagnosis and testing (continued).

  • Page 285

    Zg cooling system 7 - 11 diagnosis and testing (continued).

  • Page 286

    7 - 12 cooling system zg diagnosis and testing (continued).

  • Page 287

    Thermostat diagnosis diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded. Because of this, lower tempera- ture gauge readings for diesel versus gasoline engines may, at times be norm...

  • Page 288

    Caution: major damage could happen if you run the engine in this condition. Testing cooling system for leaks ultraviolet light method all jeep y models have a leak detection additive added to the cooling system before they leave the fac- tory. The additive is highly visible under ultraviolet light (...

  • Page 289

    Internal leakage inspection remove the oil pan drain-plug and drain a small amount of engine oil. Coolant, being heavier will drain first, or operate engine to churn oil, then exam- ine dipstick for water globules. Operate the engine without the pressure/vent cap on the coolant tank until thermostat...

  • Page 290

    Serpentine drive belt diagnosis 7 - 16 cooling system zg diagnosis and testing (continued).

  • Page 291

    Service procedures coolant level check the coolant level is checked and adjusted at the pressurized coolant tank. The tank is located at the right-rear side of the engine compartment and is mounted as the highest point of the cooling system. This will allow any air or vapor exceeding the pres- sure/...

  • Page 292

    (1) tighten the radiator draincock and (if removed), the cylinder block drain-plug. (2) remove the plastic radiator fill vent valve (unscrews counter- clockwise) from the radiator. The fill vent valve is located on the top of the right radi- ator tank (fig. 13). (3) with the fill vent valve removed,...

  • Page 293

    Removal (1) disconnect negative battery cable at battery. (2) observe the previous warnings. (3) drain cooling system. Refer to draining cool- ing system in this group. (4) remove the upper fan shroud-to-upper cross- member mounting bolts. One of the bolts is mounted vertically at the bottom of the ...

  • Page 294

    (4) do not unbolt fan blade assembly from viscous fan drive at this time. (5) remove the fan shroud mounting bolts. One of the bolts is mounted vertically at the bottom of shroud. (6) remove fan shroud and fan blade/viscous fan drive assembly as a complete unit from vehicle. (7) after removing fan b...

  • Page 295

    Occur when ambient (outside air temperature) is very high. • engine loads and temperatures are high such as when towing a trailer. • cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged (warm) position. This can occur during the first 15 seconds to one m...

  • Page 296

    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. Automatic belt tensioner water pump removal the water pump can be removed without dischar...

  • Page 297

    (8) remove the drive belt by removing the auto- matic belt tensioner. For procedures, refer to belt removal/installation in the engine accessory drive belts section of this group. Warning: constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools...

  • Page 298

    (4) position the metal coolant tube and its mount- ing bracket to the pump. (5) install the four water pump mounting bolts. Tighten bolts to 24 n·m (18 ft. Lbs.) torque. (6) install drain hose to vent tube at bottom of pump. (7) position the water pump pulley to the water pump. (8) install the water...

  • Page 299

    Motion of opposite blades should not exceed 2.0 mm (.090 inch). Test all blades in this manner. Warning: do not attempt to bend or straighten fan blades if not within speci- fications. (4) inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. Cauti...

  • Page 300

    Group. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on the 2.5l die- sel engine. Specifications cooling system capacity 2.5l diesel engine: 9.8 liters (10.4 qts.) thermostat starts to open at 80°c (176°f). Torque specifications description torque automatic belt tensi...

  • Page 301: Battery

    Battery contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation battery mounting . . . . . . . . . . . . . . . . . . . . 3 battery size and ratings . . . . . . ....

  • Page 302

    The indicator will reveal the battery condition. See built-in test indicator in this group for more infor- mation. The factory-installed batteries in vehicles built outside of north america do not have a built-in test indicator. It is important that the battery, starting, and charging systems be tho...

  • Page 303

    Deliver for thirty seconds at -18° c (0° f). Terminal voltage must not fall below 7.2 volts during or after the thirty second discharge period. The cca required is generally higher as engine displacement increases, depending also upon the starter current draw requirements. Reserve capacity the reser...

  • Page 304

    • the built-in test indicator has a black or dark color visible. • the temperature corrected specific gravity is less than 1.235. • the open-circuit voltage is less than 12.4 volts. A battery that will not accept a charge is faulty, and must be replaced. Further testing is not required. A fully-char...

  • Page 305

    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 ...

  • Page 306

    Abnormal battery discharging any of the following conditions can result in abnor- mal battery discharging: 1. Corroded or loose battery posts and terminal clamps. 2. A loose or worn generator drive belt. 3. Electrical loads that exceed the output of the charging system. This can be due to equipment ...

  • Page 307

    Trolyte. This test cannot be performed on maintenance-free batteries with non-removable cell caps. If the battery has non-removable cell caps, see the built-in test indicator or the open-circuit volt- age test procedures in this group. Specific gravity is a comparison of the density of the electroly...

  • Page 308

    Example: a battery is tested at -12.2° c (10° f) and has a specific gravity of 1.240. Determine the actual specific gravity as follows: (1) determine the number of degrees above or below 26.7° c (80° f): 26.6° c - -12.2° c = 38.8° c (80° f - 10° f = 70° f) (2) divide the result from step 1 by 5.5 (1...

  • Page 309

    Load test a battery load test will verify the battery cranking capacity. The test is based on the cold cranking amperage (cca) rating of the battery. Refer to the battery label, or see the battery classifications and ratings chart in specifications at the back of this group for the cca rating of the...

  • Page 310

    Minutes prior to the test, the battery will be some- what warmer. See the load test temperature chart for the proper loaded voltage reading. (7) if the voltmeter reading falls below 9.6 volts, at a minimum battery temperature of 21° c (70° f), the battery is faulty and must be replaced. Ignition-off...

  • Page 311

    Reading now becomes very low or non-existent, refer to group 8c - charging system to diagnose the faulty charging system. After the high-amperage iod has been corrected, switch the multi-meter to pro- gressively lower amperage scales and, if necessary, repeat the fuse and circuit breaker removal pro...

  • Page 312

    Cable clamp (fig. 11). Rotate and hold the ignition switch in the start position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and the terminal post. (2) connect the positive lead of the voltmeter to the battery positive terminal post. Connect the n...

  • Page 313

    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 no...

  • Page 314

    May be good and the charging should be completed in the normal manner. Charging time required the time required to charge a battery will vary, depending upon the following factors: • battery capacity - a completely discharged heavy-duty battery requires twice the charging time of a small capacity ba...

  • Page 315

    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 holddowns and remove the battery from the vehicle ...

  • Page 316

    Tive cable terminal clamp. Tighten both cable termi- nal clamp bolts to 8.5 n·m (75 in. Lbs.). (14) apply a thin coating of petroleum jelly or chassis grease to the exposed surfaces of the cable terminal clamps and battery terminal posts. Fig. 20 clean battery - typical test indica- tor battery clea...

  • Page 317

    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 u...

  • Page 319: Starting Systems

    Starting systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation starter relay . . . . . . . . . . . . . . . . . . . . . . . . 2 starter . . . . . . . . ...

  • Page 320

    Description and operation starting system the starting system components form two separate circuits. A high-amperage feed circuit that feeds the starter between 150 and 350 amperes, and a low-am- perage control circuit that operates on less than 20 amperes. If the vehicle is equipped with an automat...

  • Page 321

    The starter relay is a electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the start position. See the diagnosis and testing sec- tion of this group for more information on the opera- tion of the starter relay. The ...

  • Page 322

    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 ...

  • Page 323

    Cold cranking test for circuit descriptions and diagrams, refer to 8w-21 - starting system in group 8w - wiring dia- grams. The battery must be fully-charged and load- tested before proceeding. Refer to group 8a - battery for more information. (1) connect a suitable volt-ampere tester to the battery...

  • Page 324

    • battery is fully-charged. Refer to group 8a - battery for more information. • fully engage the parking brake. • if the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the park position. If the vehicle is equipped with a man- ual transmission, place the gea...

  • Page 325

    Above 0.2 volt, correct the poor starter to engine block ground contact. If the resistance tests detect no feed circuit prob- lems, remove the starter and see the solenoid test procedure in this group. Control circuit test for circuit descriptions and diagrams, refer to 8w-21 - starting system in gr...

  • Page 326

    Relay test the starter relay is located in the power distribu- tion center (pdc) in the engine compartment. Refer to the pdc label for starter relay identification and location. Remove the starter relay from the pdc as described in this group to perform the following tests: (1) a relay in the de-ene...

  • Page 327

    (3) check for continuity between the two cavities in the switch-half of the wire harness connector with the clutch pedal released. There should be no conti- nuity. If ok, go to step 4. If not ok, replace the faulty switch. (4) check for continuity between the two cavities in the switch-half of the w...

  • Page 328

    • front starter support bracket bolt - 47 n·m (35 ft. Lbs.). 4.0l engine (1) disconnect and isolate the battery negative cable. (2) raise and support the vehicle. (3) remove the battery cable and wire harness connection from the starter solenoid (fig. 13). (4) remove the front starter mounting bolt ...

  • Page 329

    Starter relay (1) disconnect and isolate the battery negative cable. (2) remove the cover from the power distribution center (pdc) (fig. 16). (3) refer to the label on the pdc for starter relay identification and location. (4) unplug the starter relay from the pdc. (5) install the starter relay by a...

  • Page 331: Starting Systems

    Starting systems contents page page removal and installation starter relay . . . . . . . . . . . . . . . . . . . . . . . . 1 starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 specifications starting system . . . . . . . . . . . . . . . . . . . . . 2 removal and installation starter...

  • Page 332

    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 ...

  • Page 333: Charging System

    Charging system contents page page general information overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation battery temperature sensor . . . . . . . . . 2 charging system operation . . . . . . . . . . 1 electronic voltage regulator . . . . . . . 2 generator . ...

  • Page 334

    Pcm. Each monitored circuit is assigned a diagnos- tic trouble code (dtc). The pcm will store a dtc in electronic memory for any failure it detects. Refer to on-board diagnostic test for charging system in this group for more information. The check gauges lamp monitors: charging sys- tem voltage, en...

  • Page 335

    (5) inspect generator drive belt condition and ten- sion. Tighten or replace belt as required. Refer to belt tension specifications in group 7, cooling sys- tem. (6) inspect automatic belt tensioner (if equipped). Refer to group 7, cooling system for information. (7) inspect connections at generator...

  • Page 336

    And the electronic voltage regulator (evr) circuitry. The second part of this test (test 2) will determine only generator amperage and will not include anal- ysis of evr circuitry. Evr circuitry is located within the powertrain control module (pcm). To test volt- age regulator circuitry, refer to th...

  • Page 337

    And a voltmeter reading of 15 volts is obtained. Immediately record ammeter reading. Do not apply load to system longer than 15 seconds as damage to test equipment may result. Caution: when adjusting rheostat load, do not allow voltage to rise above 16 volts. Damage to the battery and electrical sys...

  • Page 338

    (6) reverse removal procedures to install. Tighten generator hardware as follows: • generator mounting bolt 5.2l/5.9l engines - 41 n·m (30 ft. Lbs.) • generator pivot bolt/nut 5.2l/5.9l engines - 41 n·m (30 ft. Lbs.) • generator mounting bolt 4.0l engine - 55 n·m (41 ft. Lbs.) • generator pivot bolt...

  • Page 339

    Battery temperature sensor the battery temperature sensor is located under vehicle battery (fig. 6) and is attached to a mounting hole on battery tray. Removal (1) remove battery. Refer to group 8a, battery for procedures. (2) disconnect sensor pigtail harness from engine wire harness. (3) pry senso...

  • Page 341: Charging System

    Charging system contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 diagnosis and testing vacuum pump test . . . . . . . . . . . . . . . . . . . . 1 removal and installation generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 specificat...

  • Page 342

    Specifications specifications battery terminal nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 n·m lower generator mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 n·m upper generator mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 343: Ignition System

    Ignition system contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation automatic shutdown (asd) relay . . . . . . 3 camshaft position sensor . . . . . . . . . . . . 3 crankshaft position sensor—4.0l engine . . . . . . . . . . ....

  • Page 344

    • ignition coil • secondary ignition cables • distributor (contains rotor and camshaft position sensor) • powertrain control module (pcm) • crankshaft position, camshaft position, throt- tle position and map sensors powertrain control module (pcm) the powertrain control module (pcm) is located in th...

  • Page 345

    Spark plug cables spark plug cables are sometimes referred to as sec- ondary ignition wires. These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables ...

  • Page 346

    Rotates 180 degrees through the sync signal genera- tor. Its signal is used in conjunction with the crank- shaft position sensor to differentiate between fuel injection and spark events. It is also used to synchro- nize the fuel injectors with their respective cylinders. When the leading edge of the...

  • Page 347

    Ondary coil cable. Refer to spark plug cables in this group. Also inspect the distributor cap and rotor for cracks or burn marks. Repair as necessary. If steady arcing occurs, connect ignition coil cable to the dis- tributor cap. (3) remove a cable from one spark plug. (4) using insulated pliers, ho...

  • Page 348

    (3) attach one lead of a voltmeter to the positive (12 volt) jumper wire. Attach the negative side of voltmeter to a good ground. Determine that sufficient battery voltage (12.4 volts) is present for the starting and ignition systems. (4) determine that sufficient battery voltage (12.4 volts) is pre...

  • Page 349

    On the end of the metal tip. The silicone-dielectric- varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred com- pound. Test the spring for insufficient tension. Replace a rotor that displays any of these ad...

  • Page 350

    (2) connect the negative (-) voltmeter lead into the ground wire. For wire identification, refer to group 8w, wiring diagrams. (3) set the voltmeter to the 15 volt dc scale. (4) 5.2l/5.9l engines: remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor r...

  • Page 351

    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. With the engine running, remove spark plug cable from spark plug (one at a time) and ho...

  • Page 352

    Cold fouling/carbon fouling cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basi- cally carbon (fig. 15). A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the ...

  • Page 353

    Chipped electrode insulator a chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap. Under certain conditions, severe detonation can also separate the insulator from the center electrode (fig. 19). Spark plugs with this condition m...

  • Page 354

    Spark plugs on 5.2l/5.9l v-8 engines, spark plug cable heat shields are pressed into the cylinder head to sur- round each cable boot and spark plug (fig. 25). If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slott...

  • Page 355

    Plug gap adjustment check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode (fig. 26). Never attempt to adjust the gap by bending the center electrode. Spark plug gap 4.0l 6–cyl. Engine: .89 mm (.035 in). 5.2l v-8 engines: 1.01 mm (.040 in...

  • Page 356

    Removal the ignition coil is mounted to a bracket on the side of the engine to the front of the distributor (fig. 28). (1) disconnect the ignition coil secondary cable from ignition coil (fig. 28). (2) disconnect engine harness connector from igni- tion coil. (3) remove ignition coil mounting bolts ...

  • Page 357

    One bolt. A wire shield/router is attached to the sen- sor (fig. 31). Removal (1) disconnect sensor pigtail harness (3–way con- nector) from main engine wiring harness. This con- nection is made near rear of distributor. (2) remove sensor mounting bolt. (3) remove wire shield and sensor. Installatio...

  • Page 358

    Distributor—5.2l/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 conven...

  • Page 359

    Rotate crankshaft in a clockwise direction, as viewed from front, until number one cylinder piston is at top of compression stroke (compression should be felt on finger with number one spark plug removed). Then continue to slowly rotate engine clockwise until indicating mark (fig. 33) is aligned to ...

  • Page 360

    Rotated. Distributor rotation is not necessary as all ignition timing requirements are handled by the powertrain control module (pcm). The position of distributor determines fuel synchro- nization only. It does not determine ignition timing. Note: do not attempt to modify this fork to attain ignitio...

  • Page 361

    36). This pin is used to temporarily hold the rotor to the cylinder number 1 firing position during distrib- utor installation. If this pin is in place, proceed to step 8. If not, proceed to next step. (4) if original distributor is to be reinstalled, such as during engine overhaul, the plastic pin ...

  • Page 362

    No adjustments are necessary. Proceed to next step. (11) install distributor holddown clamp and bolt. Tighten bolt to 23 n·m (17 ft. Lbs.) torque. (12) remove pin punch tool from distributor. Or, if plastic alignment pin was used, remove it straight down from bottom of distributor. Discard plastic p...

  • Page 363

    Ignition switch removal (1) remove key lock cylinder. Refer to previous steps. (2) remove 3 ignition switch mounting screws (fig. 45). Use tamper proof torx bit (snap-on t sdmtr10 or equivalent) to remove screws. (3) gently pull switch away from column. Release connector locks on 7-terminal wiring c...

  • Page 364

    (5) automatic transmission only: before attaching ignition switch to steering column, the transmission shifter must be in park position. The park lock dowel pin on rear of ignition switch (fig. 50) must also be properly indexed into the park lock linkage (fig. 51) before installing switch. (6) the f...

  • Page 365

    (d) install 3 ignition switch mounting screws. Tighten screws to 3 n·m 6 .5 n·m (26 in. Lbs. 6 4 in. Lbs.) torque. (11) connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. (12) install steering column covers (shrou...

  • Page 366

    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 250 ohms per inch 1000 ohms per inch 3000 ohms per foot 12,000 ohms per foot c...

  • Page 367: Instrument Panel Systems

    Instrument panel systems contents page page general information body control module . . . . . . . . . . . . . . . . 4 gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 graphic display module . . . . . . . . . . . . . . 3 indicator lamp . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 368

    General information introduction this group is responsible for covering the vehicle instrument panel. However, because the instrument panel serves as the command center of the vehicle, it is a very complex unit. The instrument panel is designed to house the controls and monitors for stan- dard and o...

  • Page 369

    • check gauges lamp • cruise-on indicator lamp • headlamp high beam indicator lamp • low fuel warning lamp • malfunction indicator (check engine) lamp • master lighting indicator lamp • seat belt reminder lamp • turn signal indicator lamps • upshift indicator lamp (manual transmission) • wait-to-sta...

  • Page 370

    Indicator lamp indicator lamps are located in the instrument clus- ter, and in the graphic display module (gdm) or the vehicle information center (vic). Those lamps within the instrument cluster are served by the clus- ter circuit board and wire harness connectors. Those lamps located in the gdm or ...

  • Page 371

    Description and operation coolant temperature gauge the coolant temperature gauge gives an indication of the engine coolant temperature. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an e...

  • Page 372

    Received from the powertrain control module (pcm) on the chrysler collision detection (ccd) data bus. The pcm uses an input from the engine oil pres- sure sensor and internal programming to decide what engine oil pressure message is required. The pcm then sends the proper message to the instru- ment...

  • Page 373

    The airbag indicator lamp also has a lamp backup feature. Following the seat belt reminder lamp dis- play function, if an inoperative airbag warning lamp circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp on and off for about t...

  • Page 374

    Vehicles equipped with the automatic headlamps option have an automatic funeral mode or parade mode. In this mode, the bcm uses an input from the automatic headlamp light sensor to determine the ambient light levels. If the bcm decides that the exterior lighting is turned on in the daylight, it over...

  • Page 375

    Tion when the exterior lamps are lighted. The lamp is hard-wired in the instrument cluster, and is com- pletely controlled by the panel lamps driver circuit. The lamp is grounded at all times and receives a pulse-width modulated battery feed from the body control module (bcm). The instrument cluster...

  • Page 376

    The pcm uses an input from the water-in-fuel sen- sor in the fuel filter/water separator to determine that excess water has accumulated in the diesel fuel. The pcm then sends the proper message to the instrument cluster on the ccd data bus to turn the lamp on or off. Refer to group 14 - fuel systems...

  • Page 377

    Performed with the drb scan tool as described in the proper body diagnostic procedures manual. Odometer and trip odometer if the problem being diagnosed is related to gauge accuracy, be certain to confirm that the problem is with the gauge and not with an incorrect speedome- ter pinion gear, axle ra...

  • Page 378

    Voltmeter if the problem being diagnosed is related to gauge accuracy, be certain to confirm proper charging sys- tem operation before considering gauge replacement. Refer to group 8c - charging system for more infor- mation. Refer to group 8w - wiring diagrams for cir- cuit descriptions and diagram...

  • Page 379

    The abs warning lamp driver circuit cavity of the cluster wire harness connector and a good ground. There should be no continuity. If ok, go to step 6. If not ok, repair the short circuit as required. (6) check for continuity between the abs warning lamp driver circuit cavities of the cluster wire h...

  • Page 380

    (3) disconnect and isolate the battery negative cable. Unplug the white 24-way body control module (bcm) wire harness connector. Check for continuity between the panel lamp driver circuit cavities of the cluster wire harness connector and the bcm wire harness connector. If ok, refer to group 8l - la...

  • Page 381

    Wire harness connector and a good ground. There should be continuity. If ok, go to step 2. If not ok, repair the open circuit as required. (2) check the transfer case switch continuity while shifting the transfer case shift lever to the proper positions. The switch continuity should be as shown in (...

  • Page 382

    Low fuel warning lamp the diagnosis found here addresses an inoperative low fuel warning lamp condition. If the problem being diagnosed is related to lamp accuracy, be cer- tain to confirm the problem is the with the low fuel warning lamp and not with the fuel gauge circuit. See the diagnosis for th...

  • Page 383

    Harness connector. If ok, refer to group 8l - lamps for diagnosis of the headlamp switch and/or the proper body diagnostic procedures manual for diag- nosis of the bcm. If not ok, repair the open circuit as required. Seat belt reminder lamp the diagnosis found here addresses an inoperative seat belt...

  • Page 384

    Coolant level low/coolant sensor bad if the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp and sensor and not with the engine coolant level. The actual engine coolant level should be checked before you proceed with lamp and sensor diagnos...

  • Page 385

    Cases, only one pair of wire harness connectors should be joined. If ok, go to step 5. If not ok, cor- rect the wire harness connections as required. (5) refer to the vic 4wd display characteristics chart (fig. 3). Check the continuity of the circuit for the indicator lamp or wheel lamp that is not ...

  • Page 386

    Warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting 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 pers...

  • Page 387

    Water accumulation in the fuel filter/water separator before attempting further diagnosis. Refer to group 14 - fuel systems for diagnosis and service of the water-in-fuel sensor. For circuit descriptions and dia- grams, refer to 8w-40 - instrument cluster in group 8w - wiring diagrams. Warning: on v...

  • Page 388

    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 rele...

  • Page 389

    Vic reset to reset vic service reminder feature after recommended service has been performed, proceed as follows. Zg instrument panel systems 8e - 23 service procedures (continued).

  • Page 390

    Removal and installation switch pod bezel warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper pre- cautions could result in accide...

  • Page 391

    Instrument cluster warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper pre- cautions could result in accidental air- bag deploymen...

  • Page 392

    Gauge warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting 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 possibl...

  • Page 393

    (4) remove the outboard switch pod from the instrument panel. (5) reverse the removal procedures to install. Inboard switch pod warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting steering wheel, steering column, or instrument panel component...

  • Page 394

    Body control module warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper pre- cautions could result in accidental air- bag deployme...

  • Page 395

    (2) remove the three screws that secure the graphic display module (gdm) or vehicle informa- tion center (vic) to the instrument panel armature (fig. 12). (3) pull the gdm or vic unit out from the instru- ment panel far enough to unplug the wire harness connector. (4) remove the gdm or vic from the ...

  • Page 396

    Cigar lighter warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting 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...

  • Page 397

    Glove box warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting 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 pos...

  • Page 398

    Glove box latch and handle (1) remove the glove box as described in this group. (2) remove the glove box hinge and glove box bin as described in this group. (3) remove the two bezel screws, two latch screws, and one handle screw from the glove box inner door panel. (4) remove the inner door panel fr...

  • Page 399

    (2) remove both switch pod bezels, the cluster bezel, the knee blocker, the glove box module, and the cowl top trim panel. See the procedures in this group. (3) if the vehicle is so equipped, remove the screw that secures the auto headlamp light sensor/vehicle theft security system lamp near the def...

  • Page 400

    (3) remove the knee blocker as described in this group. (4) remove the bolts that secure the lower instru- ment panel reinforcement to the instrument panel armature and remove the reinforcement (fig. 24). (5) remove the upper and lower steering column shrouds. Refer to group 19 - steering for the pr...

  • Page 401

    (20) remove the two bolts that secure the ends of the instrument panel armature to the cowl side pan- els. (21) remove the cowl top trim panel as described in this group. (22) remove the two bolts that secure the ends of the instrument panel armature to the windshield fence. (23) remove the four nut...

  • Page 403: Instrument Panel Systems

    Instrument panel systems contents page page general information body control module . . . . . . . . . . . . . . . . 4 gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 graphic display module . . . . . . . . . . . . . . 3 indicator lamp . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 404

    General information introduction this group is responsible for covering the vehicle instrument panel. However, because the instrument panel serves as the command center of the vehicle, it is a very complex unit. The instrument panel is designed to house the controls and monitors for stan- dard and o...

  • Page 405

    • check gauges lamp • cruise-on indicator lamp • headlamp high beam indicator lamp • low fuel warning lamp • malfunction indicator (check engine) lamp • master lighting indicator lamp • seat belt reminder lamp • turn signal indicator lamps • upshift indicator lamp (manual transmission) • wait-to-sta...

  • Page 406

    Within the instrument cluster are served by the clus- ter circuit board and wire harness connectors. Those lamps located in the gdm or vic modules are served by the gdm or vic circuit board and wire harness connectors. Most of the indicator lamps in the instrument clus- ter and vic module are contro...

  • Page 407

    Description and operation coolant temperature gauge the coolant temperature gauge gives an indication of the engine coolant temperature. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an e...

  • Page 408

    Received from the powertrain control module (pcm) on the chrysler collision detection (ccd) data bus. The pcm uses an input from the engine oil pres- sure sensor and internal programming to decide what engine oil pressure message is required. The pcm then sends the proper message to the instru- ment...

  • Page 409

    The airbag indicator lamp also has a lamp backup feature. Following the seat belt reminder lamp dis- play function, if an inoperative airbag warning lamp circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp on and off for about t...

  • Page 410

    Vehicles equipped with the automatic headlamps option have an automatic funeral mode or parade mode. In this mode, the bcm uses an input from the automatic headlamp light sensor to determine the ambient light levels. If the bcm decides that the exterior lighting is turned on in the daylight, it over...

  • Page 411

    Tion when the exterior lamps are lighted. The lamp is hard-wired in the instrument cluster, and is com- pletely controlled by the panel lamps driver circuit. The lamp is grounded at all times and receives a pulse-width modulated battery feed from the body control module (bcm). The instrument cluster...

  • Page 412

    The pcm uses an input from the water-in-fuel sen- sor in the fuel filter/water separator to determine that excess water has accumulated in the diesel fuel. The pcm then sends the proper message to the instrument cluster on the ccd data bus to turn the lamp on or off. Refer to group 14 - fuel systems...

  • Page 413

    Odometer and trip odometer if the problem being diagnosed is related to gauge accuracy, be certain to confirm that the problem is with the gauge and not with an incorrect speedome- ter pinion gear, axle ratio, or tire size. Refer to group 21 - transmission for more information on the speed- ometer p...

  • Page 414

    Warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint 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 pers...

  • Page 415

    Brake warning lamp the diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the on position and the parking brake released, or comes on while driving, refer to group 5 - brakes for diagnosis. If no service brake or...

  • Page 416

    8h - vehicle speed control and/or to the proper pow- ertrain diagnostic procedures manual for diagnosis. For circuit descriptions and diagrams, refer to 8w-33 - vehicle speed control and 8w-40 - instrument cluster in group 8w - wiring diagrams. Warning: on vehicles equipped with air- bags, refer to ...

  • Page 417

    Case wire harness connectors. Connect the battery negative cable and check the operation of the inoper- ative lamp. If ok, discard the faulty bulb. If not ok, replace the faulty gdm. Headlamp high beam indicator lamp the diagnosis found here addresses an inoperative headlamp high beam indicator lamp...

  • Page 418

    Warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint 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 pers...

  • Page 419

    Warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint 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 pers...

  • Page 420

    (1) unplug the coolant level sensor wire harness connector on the coolant reserve bottle. Check for continuity between the ground circuit cavity of the wire harness connector and a good ground. There should be continuity. If ok, go to step 2. If not ok, repair the open circuit as required. (2) with ...

  • Page 421

    Programming, and inputs from the combination flasher on the fused ignition switch output (l5) cir- cuit, and a vehicle speed sensor (distance) message received on the ccd data bus from the powertrain control module to control this message. If testing of the l5 circuit between the vic module wire har...

  • Page 422

    Warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint 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 pers...

  • Page 423

    Vic initial set-up zg instrument panel systems 8e - 21 service procedures (continued).

  • Page 424

    Vic reset 8e - 22 instrument panel systems zg service procedures (continued).

  • Page 425

    Removal and installation switch pod bezel warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting steering wheel, steering column, or instrument panel com- ponent diagnosis or service. Failure to take the proper precautions could result in accide...

  • Page 426

    Instrument cluster warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint 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 ...

  • Page 427

    (3) remove the gauge(s) from the front of the clus- ter circuit and gauge housing. (4) reverse the removal procedures to install. Cluster bulb warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting steering wheel, steering column, or instrument ...

  • Page 428

    (3) unplug the bulb from the holder. 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. (4) reverse the removal procedures to install. Outboard switch pod warn...

  • Page 429

    Glove box module warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint 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 an...

  • Page 430

    Glove box lamp and switch warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint 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 depl...

  • Page 431

    Power outlet warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint 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 po...

  • Page 432

    (1) disconnect and isolate the battery negative cable. (2) drill out the two rivets that secure the glove box hinge to the lower edge of the glove box module (fig. 17). Note: the rivets are used to ease assembly during the manufacturing process, but do not require replacement following service. (3) ...

  • Page 433

    (3) insert a small screwdriver into the retaining tumbler release slot and depress the retaining tum- bler (fig. 20). (4) pull the lock cylinder out of the latch handle by using a gentle twisting and pulling action on the key. (5) reverse the removal procedures to install. Cowl top trim panel warnin...

  • Page 434

    (3) remove the push nut that secures the right cowl side trim panel to the junction block stud (fig. 22). (4) remove the two screws that secure the right cowl side trim panel to the right front door opening trim. (5) remove the right cowl side trim panel. (6) unplug all of the wire harness connector...

  • Page 435

    (14) unplug all of the instrument panel wire har- ness connectors from the junction block on the right cowl side panel. (15) if the vehicle is so equipped, disconnect the in-car temperature sensor aspirator hose at the cou- pling near the passenger side of the transmission floor tunnel. (16) on left...

  • Page 437: Audio Systems

    Audio systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 memory system . . . . . . . . . . . . . . . . . . . . . . 1 description and operation antenna relay . . . . . . . . . . . . . . . . . . . . . . . 3 antenna . . . . . . . . . . . . . . ...

  • Page 438

    Description and operation radio factory-installed receiver availability for this model is affected by the country for which the vehicle is manufactured. Available factory-installed radio receivers for vehicles destined for sale in north america include an am/fm/cassette (ras sales code), an am/fm/ca...

  • Page 439

    Ignition-off draw fuse all vehicles are equipped with an ignition-off draw (iod) fuse that is removed when the vehicle is shipped from the factory. This fuse feeds various accessories that require battery current when the ignition switch is in the off position, including the clock and radio station ...

  • Page 440

    Rent and ground to the proper brushes of the revers- ible power antenna motor when the ignition switch and radio switch are turned to the on or off posi- tions. See the diagnosis and testing section of this group for more information on the operation of the antenna relay. The antenna relay is locate...

  • Page 441

    Audio system diagnosis condition possible cause correction 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 connecto...

  • Page 442

    Radio if the vehicle is equipped with remote radio switches located on the backs of the steering wheel spokes, and the problem being diagnosed is related to one of the symptoms listed below, be certain to check the remote radio switches and circuits as described in this group, prior to attempting ra...

  • Page 443

    Ok, go to step 7. If not ok, repair the short circuit as required. (7) check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the bcm wire harness connec- tor. There should be continuity. If ok, refer to the proper body diagnostic pr...

  • Page 444

    Wire harness connectors for continuity to ground. In each case there should be no continuity. If ok, go to step 13. If not ok, repair the short circuit as required. (13) for each inoperative speaker location, check the resistance between the amplified feed (+) circuit and the amplified return (-) ci...

  • Page 445

    (3) if the resistance is more than one ohm, check the braided ground strap connected to the engine and the vehicle body for being loose, corroded, or dam- aged. Repair the ground strap connection, if required. Test 4 test 4 checks the condition of the ground between the antenna base and the vehicle ...

  • Page 446

    Radio frequency interference 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-...

  • Page 447

    (7) if the vehicle is so equipped, remove the screw that secures the ground wire to the radio chassis and remove the radio from the vehicle. (8) reverse the removal procedures to install. Tighten the radio mounting screws to 5 n·m (45 in. Lbs.). Remote radio switch warning: on vehicles equipped with...

  • Page 448

    (2) disengage the left rear seat cushion latch by pulling upward on the release strap. Tilt the seat cushion forward. (3) lift the carpeting in the under-seat area as required to access the amplifier. (4) unplug the two wire harness connectors from the amplifier (fig. 8). (5) remove the three screws...

  • Page 449

    (7) remove the speaker from the instrument panel. (8) reverse the removal procedures to install. Front door (1) disconnect and isolate the battery negative cable. (2) remove the bezel near the inside door latch release handle by inserting a straight-bladed screw- driver in the notched end and prying...

  • Page 450

    (4) remove the trim cap and screw near the rear of the door armrest. (5) using a wide flat-bladed tool such as a trim stick, gently pry the trim panel away from the door around the perimeter to release the trim panel retainers. Note: to aid in the removal of the trim panel, start at the bottom of th...

  • Page 451

    (3) remove the five screws that secure the sound bar to the upper liftgate opening reinforcement. (4) lower the sound bar far enough to unplug the wire harness connector near the right end of the sound bar. (5) remove the sound bar from the vehicle. (6) reverse the removal procedures to install. Whe...

  • Page 452

    (2) remove the right front inner fender liner. Refer to group 23 - body for the procedures. (3) remove the antenna cap nut and escutcheon using an antenna nut wrench (special tool c-4816) (fig. 22). (4) remove the fuse access panel in the right cowl side trim panel, and remove the push nut that secu...

  • Page 453

    (10) pull the antenna wire harness and coaxial cable out through the right cowl side outer panel and remove the power antenna unit from the vehicle. (11) reverse the removal procedures to install. Tighten the hardware as follows: • antenna cap nut - 7.9 n·m (70 in. Lbs.) • antenna mounting bolts - 8...

  • Page 455: Horn Systems

    Horn systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation body control module . . . . . . . . . . . . . . . . 2 horn relay . . . . . . . . . . . . . . . . . . . . . . . . . . 1 horn switch . . . . . . . . . . . . . . ...

  • Page 456

    Body control module a body control module (bcm) is used on this model to control and integrate many of the electronic functions and features included on the vehicle. The bcm contains a central processing unit and inter- faces with other modules in the vehicle on the chrysler collision detection (ccd...

  • Page 457

    (5) the coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. It can also be grounded by the body con- trol module (bcm) in response to inputs from the vehicle theft security system (vtss) or the remote key...

  • Page 458

    (8) test the relay operation. 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 pr...

  • Page 459

    Vehicle speed control system contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation powertrain control module (pcm) . . . . 2 servo cable . . . . . . . . . . . . . . . . . . . . . . . . . 2 speed control servo . . . . . . . . ....

  • Page 460

    Servo cable the speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Powertrain control ...

  • Page 461

    • a two-digit number flashed on the malfunction indicator (check engine) lamp • a two-digit number displayed on the vehicle odometer • a description of the dtc can be read using the drb scan tool refer to the following speed control system diag- nostic trouble code chart for dtc’s which apply to the...

  • Page 462

    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 ...

  • Page 463

    Speed control electrical test two different test methods may be used to check the electronic speed control system. One involves using the drb scan tool. If this test method is desired, refer to the appropriate powertrain diagnos- tic procedures service manual. The other test method will involve the ...

  • Page 464

    The engine must be started and running for the following voltage tests. (1) start engine. (2) disconnect 4–way electrical connector at servo (fig. 2). (3) turn speed control switch to on position. (4) check for battery voltage at pin–3 of wiring harness 4–way connector (fig. 3). This is the 12 volt ...

  • Page 465

    (7) remove clip attaching cable to servo. (8) remove servo from mounting bracket. Installation (1) position servo to mounting bracket. (2) block throttle to full open position to align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip. (3) install servo mounting n...

  • Page 466

    (6) remove servo cable from servo. Refer to speed control servo removal and installation in this group. Installation (1) install end of cable to speed control servo. Refer to speed control servo removal and installa- tion in this group. (2) install cable into throttle body mounting bracket (snaps in...

  • Page 467

    Specifications torque chart description torque servo mounting bracket-to-servo nuts . . . . . . . . . . . . . . . . . . . 8.5 n·m (75 in. Lbs.) servo mounting bracket-to-body nuts . . . . . . . . . . . . . . . . . . . . . 5 n·m (47 in. Lbs.) switch module mounting screws . . . . . . . . . . . . . . ...

  • Page 469

    Vehicle speed control system contents page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 general information introduction this group covers both left-hand drive (lhd) and right-hand drive (rhd) versions of this model. Whenever feasible, the rhd versions of affect...

  • Page 471

    Turn signal and hazard warning systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation combination flasher . . . . . . . . . . . . . . . . . 1 hazard warning system . . . . . . . . . . . . . . 1 turn signal indicator lam...

  • Page 472

    If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically compensate. This allows the flash rate to remain the same, regardless of electrical load increases. How- ever, if a bulb fails in the turn signal ...

  • Page 473

    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 ...

  • Page 474

    Removal and installation combination flasher 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...

  • Page 475

    (9) test the flasher operation. (10) install the right cowl side trim panel and the fuse access panel. Multi-function switch warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting any steering wheel, steering column, or instrument panel componen...

  • Page 476

    (14) gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. (15) unplug the wire harness connector from the multi-function switch. (16) reverse the removal procedures to install. Tighten the fasteners as follows: • m...

  • Page 477: Wiper And Washer Systems

    Wiper and washer systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation body control module . . . . . . . . . . . . . . . . 3 intermittent wipe relay . . . . . . . . . . . . . . 4 rear wiper and washer system . . . . . ...

  • Page 478

    The washers will operate only when the ignition switch is in the accessory or on positions. A circuit breaker located in the junction block protects the cir- cuitry of the washer system. Refer to the owner’s manual for more information on the windshield washer system controls and operation. Rear wip...

  • Page 479

    Where a nut secures the wiper motor crank arm to the motor output shaft. Wiper speed is controlled by current flow to the proper set of brushes. The wiper motor completes its wipe cycle when the windshield wiper (multi-func- tion) switch is turned to the off position, and parks the blades in the low...

  • Page 480

    Modes. On models with the optional automatic head- lamps, the bcm can be programmed to automatically turn on the headlamps when the windshield wipers are turned on. Refer to the proper body diagnostic procedures manual for more information on enabling or disabling this feature. The bcm is programmed...

  • Page 481

    Nozzle snaps into a hole in the liftgate outer panel, above the liftgate glass. The washer nozzle is not adjustable. The nozzle, check valve, and hose fittings cannot be repaired and, if faulty or damaged, they must be replaced. Diagnosis and testing wiper system front if the problem being diagnosed...

  • Page 482

    (d) check for battery voltage at the wiper park switch sense circuit cavity of the wiper motor wire harness connector with the wiper switch in the low or high position, then move the switch to the off position. The meter should switch between bat- tery voltage and zero volts while the wipers are cyc...

  • Page 483

    Zero ohms. If ok, go to step 4. If not ok, repair the ground circuit as required. (4) connect the battery negative cable. Turn the ignition switch to the on position. Depress the washer switch. Measure the voltage at the washer switch output circuit cavity of the front washer pump wire harness conne...

  • Page 484

    (2) using an ohmmeter, check the switch continu- ity at the switch terminals as follows: a. With the switch in the off position, there should be no continuity between any two switch terminals. B. With the switch knob depressed in the wash position, there should be continuity between the fused igniti...

  • Page 485

    (bcm) wire harness connector at all times. If ok, go to step 3. If not ok, repair the open circuit(s) to the wiper motor and bcm as required. (3) the relay normally open terminal (87) is con- nected to the common feed terminal (30) in the ener- gized position. There should be battery voltage at the ...

  • Page 486

    To remove the rear wiper blade and/or element, proceed as follows: (1) lift the rear wiper arm to raise the wiper blade and element off of the liftgate glass. (2) remove the wiper blade from the wiper arm, or the wiper element from the wiper blade as follows: (a) to remove the wiper blade from the w...

  • Page 487

    Blade in the installation position on the ramp (fig. 8) and tighten the retaining nut to 18 n·m (160 in. Lbs.). (4) close the pivot cover and move the rear wiper blade to the park position on the ramp. Wiper motor front (1) disconnect and isolate the battery negative cable. (2) remove the wiper arms...

  • Page 488

    (9) reverse the removal procedures to install. Tighten the mounting hardware as follows: • motor mounting screws - 1 to 1.7 n·m (10 to 15 in. Lbs.) • motor mounting nut - 4 to 5.6 n·m (35 to 50 in. Lbs.). Wiper linkage and pivot the wiper linkage and pivots can only be removed from or installed in t...

  • Page 489

    Wiper switch and washer switch front 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 acciden...

  • Page 490

    (15) unplug the wire harness connector from the multi-function switch. (16) reverse the removal procedures to install. Tighten the fasteners as follows: • multi-function switch wire harness connector screw - 2 n·m (17 in. Lbs.) • multi-function switch retaining screws - 2 n·m (17 in. Lbs.) • steerin...

  • Page 491: Lamps

    Lamps contents page page bulb application . . . . . . . . . . . . . . . . . . . . . 19 headlamp alignment . . . . . . . . . . . . . . . . . . 7 lamp bulb service . . . . . . . . . . . . . . . . . . . 10 lamp diagnosis . . . . . . . . . . . . . . . . . . . . . . . 1 lamp service . . . . . . . . . . ....

  • Page 492

    Headlamp diagnosis headlamp diagnosis condition possible causes correction 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 ...

  • Page 493

    Fog lamp diagnosis condition possible causes correction 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 ...

  • Page 494

    Daytime running lamp diagnosis daytime running lamp diagnosis condition possible causes correction 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....

  • Page 495

    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 repla...

  • Page 496

    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. Con...

  • Page 497

    Headlamp alignment index page page general information headlamp alignment . . . . . . . . . . . . . . . . . . 7 service procedures fog lamp adjustment . . . . . . . . . . . . . . . . . 9 headlamp adjustment using alignment screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 headlamp a...

  • Page 498

    (6) fuel tank should be full. Add 2.94 kg (6.5 lbs.) of weight over the fuel tank for each estimated gallon of missing fuel. Alignment screen preparation (1) position vehicle on a level surface perpendicu- lar to a flat wall 7.62 meters (25 ft) away from front of headlamp lens (fig. 1). (2) if neces...

  • Page 499

    Fog lamp adjustment prepare an alignment screen. A properly aligned fog lamp will project a pattern on the alignment screen 100 mm (4 in.) below the fog lamp centerline and straight ahead (fig. 3). Rotate the adjustment screw (fig. 4) to obtain the correct pattern. Special tools special tools—headla...

  • Page 500

    Lamp bulb service index page page removal and installation cargo lamp bulb . . . . . . . . . . . . . . . . . . . . 12 center high mounted stop lamp (chmsl) bulb . . . . . . . . . . . . . . . . . . . . . . . 11 dome lamp bulb . . . . . . . . . . . . . . . . . . . . . 12 door courtesy lamp bulb . . . ...

  • Page 501

    Installation caution: do not touch the bulb glass with fin- gers or other oily surfaces. Reduced bulb life will result. (1) position bulb element in fog lamp. (2) connect wire connectors at bulb. (3) install spring clip securing bulb to fog lamp. (4) install screws attaching the access cover to the ...

  • Page 502

    Installation (1) insert the replacement bulb in the lamp base socket. Rotate it clockwise. (2) connect the wire harness connector to the lamp. Visor vanity lamp bulb removal (1) using a small flat blade, carefully pry each cor- ner of lens outward from lamp. (2) separate lens from lamp. (3) grasp bu...

  • Page 503

    Lamp service index page page removal and installation cargo lamp . . . . . . . . . . . . . . . . . . . . . . . . . 16 center high mounted stop lamp (chmsl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 dome/reading lamp . . . . . . . . . . . . . . . . . . 15 door courtesy lamp . . . . ....

  • Page 504

    (4) remove sidemarker socket from lamp. (5) separate lamp from vehicle. Installation (1) install turn signal lamp socket. (2) install side marker lamp socket. (3) slide lamp into slot provided on inboard side of headlamp assembly. (4) install screws. (5) install parking lamp. Tail, stop, turn signal...

  • Page 505

    Center high mounted stop lamp (chmsl) removal (1) raise liftgate. (2) remove upper liftgate trim panel. (3) remove chmsl lamp mounting screws (fig. 5). (4) remove chmsl lamp. (5) turn bulb socket 1/4 turn counterclockwise. (6) separate socket from lamp. Installation (1) position socket in lamp. (2) ...

  • Page 506

    (4) install the lamp housing screws. (5) position dome lamp lens at lamp housing. Snap lens into housing. Door courtesy lamp removal (1) remove door trim panel. Refer to group 23, body components for service procedure. (2) remove bulb socket from lamp. (3) depress lamp locking tabs and separate lamp...

  • Page 507

    Lamp systems index page page general information auto headlamp sensor . . . . . . . . . . . . . . 17 daytime running lamp system . . . . . . . . 17 lamp outage module . . . . . . . . . . . . . . . . . 17 removal and installation auto headlamp sensor . . . . . . . . . . . . . . 17 daytime running lig...

  • Page 508

    Installation (1) reverse the removal procedure. Lamp outage module removal (1) disconnect battery negative cable. (2) remove spare tire from carrier. (3) remove access door. (4) remove screw holding module to inner quarter panel (fig. 2). (5) disconnect wiring connectors at module. (6) separate lamp...

  • Page 509

    Bulb application index page page general information general information . . . . . . . . . . . . . . . . 19 specifications exterior lamps . . . . . . . . . . . . . . . . . . . . . 19 interior lamps . . . . . . . . . . . . . . . . . . . . . . 19 general information general information the following b...

  • Page 511: Lamps

    Lamps contents page page bulb application . . . . . . . . . . . . . . . . . . . . . . 9 lamp bulb service . . . . . . . . . . . . . . . . . . . . . 4 lamp diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 1 lamp service . . . . . . . . . . . . . . . . . . . . . . . . . . 6 lamp systems . . ....

  • Page 512

    Service procedures index page service procedures headlamp alignment . . . . . . . . . . . . . . . . . . 2 service procedures headlamp alignment vehicle preparation (1) verify headlamp dimmer switch and high beam indicator operation. (2) if equipped with a motorized headlamp leveling system, ensure t...

  • Page 513

    (5) jounce front suspension three times by pushing downward on front bumper and releasing. (6) measure the distance from the center of head- lamp lens to the floor. Transfer measurement to the alignment screen (with tape). (7) place a tape line 150 mm below and parallel to the center of headlamp len...

  • Page 514

    Lamp bulb service index page page removal and installation headlamp bulb . . . . . . . . . . . . . . . . . . . . . . . . 4 rear fog lamp bulb . . . . . . . . . . . . . . . . . . . 5 side repeater lamp bulb . . . . . . . . . . . . . . 4 removal and installation headlamp bulb removal (1) remove headla...

  • Page 515

    Rear fog lamp bulb removal (1) remove the tail lamp. (2) grasp the fog lamp bulb socket and rotate counterclockwise (fig. 4). Separate socket from lamp. (3) rotate bulb in the socket counterclockwise and remove bulb from socket. Installation (1) position the bulb in the socket and rotate clock- wise...

  • Page 516

    Lamp service index page page removal and installation headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 rear bumper reflector . . . . . . . . . . . . . . . 6 rear fog lamp . . . . . . . . . . . . . . . . . . . . . . . . 6 side repeater lamp . . . . . . . . . . . . . . . . . . . 6 ...

  • Page 517

    Installation (1) position the reflector on the rear bumper (fig. 3). (2) install the nut attaching the reflector to the rear bumper. Fig. 3 rear bumper reflector zg lamps 8l - 7 removal and installation (continued).

  • Page 518

    Lamp systems index page removal and installation headlamp leveling motor . . . . . . . . . . . . . 8 removal and installation headlamp leveling motor removal (1) remove headlamp. (2) remove screws attaching leveling motor to grille opening reinforcement (gor) (fig. 1). (3) gently push leveling motor...

  • Page 519

    Bulb application index page specifications exterior lamps . . . . . . . . . . . . . . . . . . . . . . . 9 specifications exterior lamps lamp bulb front fog lamp . . . . . . . . . . . . . . . . . . . . . . . . . H3 front turn signal lamp . . . . . . . . . . . . . . . . . P21w headlamp . . . . . . . ....

  • Page 521: Passive Restraint Systems

    Passive restraint systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation airbag control module . . . . . . . . . . . . . . 3 airbag module . . . . . . . . . . . . . . . . . . . . . . . 2 clockspring . . . . . . . . . . ...

  • Page 522

    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 ...

  • Page 523

    Storage an airbag module must be stored in its original, special container until used for service. Also, it must be stored in a clean, dry environment; away from sources of extreme heat, sparks, and high electrical energy. Always place or store an airbag module on a surface with its trim cover or ai...

  • Page 524

    Then go out. This indicates that the airbag system is functioning normally. 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 n...

  • Page 525

    Vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. Be sure to vacuum the heater and air conditioning outlets as well (fig. 3). Run the heater and air con- ditioning blower on the lowest speed setting and vac- uum any powder expelled from the outlets. You m...

  • Page 526

    (2) remove the instrument panel top pad. Refer to group 8e - instrument panel systems for the proce- dures. (3) remove the two screws that secure the airbag module to the front airbag mounting bracket (fig. 5). (4) remove the two screws that secure the airbag module to the rear airbag mounting brack...

  • Page 527

    (8) when installing the trim cover and horn switch, be certain that the locking blocks are fully engaged on the lip of the airbag housing (fig. 9). (9) when installing the upper and lower trim cover retainers, be certain that the tabs on each retainer are engaged in the retainer slots of the trim co...

  • Page 528

    (2) remove the screws that secure the instrument panel wire harness trough to the airbag rear mount- ing bracket. (3) remove the heater-a/c control from the instru- ment panel. Refer to group 24 - heating and air conditioning for the procedures. (4) reach through the heater-a/c control opening in th...

  • Page 529

    (8) remove the four screws that secure the acm mounting bracket to the floor pan transmission tun- nel (fig. 14). (9) remove the acm and mounting bracket as a unit. (10) when installing the acm, position the unit with the arrow on the acm housing pointing for- ward. (11) attach the acm to the floor ...

  • Page 530

    (1) turn the steering wheel until the front wheels are in the straight-ahead position before starting the procedure. (2) disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. (3) remove t...

  • Page 531

    (2) disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. (3) remove the airbag module as described in this group. (4) if the vehicle is so equipped, unplug the wire harness connectors fr...

  • Page 533

    Electrically heated systems contents page page defogger system . . . . . . . . . . . . . . . . . . . . . 1 heated seats . . . . . . . . . . . . . . . . . . . . . . . . . . 7 defogger system index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description...

  • Page 534

    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 represen...

  • Page 535

    By controlling the current feeds to their respective outside rear view mirror heating elements. The bcm is mounted under the driver side out- board end of the instrument panel, behind the instru- ment panel support armature and below the outboard switch pod. Refer to group 8e - instrument panel syst...

  • Page 536

    Not change. If ok, go to step 4. If not ok, repair the circuit to ground as required. (4) connect the negative lead of the voltmeter to the right side bus bar and touch each grid line at midpoint c with the positive lead. A reading of approximately six volts indicates a line is good. A reading of ze...

  • Page 537

    Gized position. This terminal supplies battery voltage to the fuse in the junction block that feeds the rear glass heating grid and the defogger switch led indi- cator. There should be continuity between the cavity for relay terminal 87 and the rear glass heating grid and defogger switch led indicat...

  • Page 538

    (9) allow the epoxy to cure 24 hours at room tem- perature, or use a heat gun with a 260° to 371° c (500° to 700° f) range for fifteen minutes. Hold the heat gun approximately 254 mm (10 in.) from the repair. (10) after the conductive epoxy is properly cured, remove the wedge or clamp from the termi...

  • Page 539

    Heated seats index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 7 description and operation heated seat control module . . . . . . . . . 8 heated seat element and sensor . . . . . . 8 heated seat switch . . . . . . . . . . . . . . . . . . . 7 diagnosis a...

  • Page 540

    Switches and their led cannot be repaired. If either switch or led is faulty, the inboard switch pod unit must be replaced. Heated seat control module the heated seat control module (hscm) is an electronic thermostatic module designed to operate the electric seat heater elements. Two modules are use...

  • Page 541

    Case, there should be no continuity. If ok, go to step 6. If not ok, replace the faulty inboard switch pod. (6) move both heated seat switches to the low position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit ter- minal and the driver heated seat switch ou...

  • Page 542

    (1) disconnect and isolate the battery negative cable. (2) using a trim stick or other suitable wide flat- bladed tool, pry gently around the edges of the inboard switch pod bezel and remove the bezel. (3) remove the three screws that secure the inboard switch pod to the instrument panel (fig. 1). (...

  • Page 543: Power Lock Systems

    Power lock systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 memory system . . . . . . . . . . . . . . . . . . . . . . 2 power liftglass release system . . . . . . 1 power lock system . . . . . . . . . . . . . . . . . . 1 remote keyless ent...

  • Page 544

    Refer to 8w-61 - power door locks in group 8w - wiring diagrams for circuit descriptions and dia- grams. Refer to group 23 - body for the power lift- glass release component service procedures. Remote keyless entry system the remote keyless entry (rke) system is a radio frequency system that allows ...

  • Page 545

    Some of the features and functions of the power lock and remote keyless entry (rke) systems made possible because of the communication of the door modules on the ccd data bus network include: • a door-lock inhibit feature which prevents the power lock system from being energized with a door switch i...

  • Page 546

    The rke system. In addition, vehicles with the optional memory system must have their access codes programmed in the rke receiver so that the molded-in numbers “1” or “2” on the back of the transmitter case coincide with the memory “1” and “2” buttons of the memory set switch in the vehicle. Transmi...

  • Page 547

    Between the ground circuit cavity of the door module wire harness connector and a good ground. There should be continuity. If ok, go to step 4. If not ok, repair the open circuit as required. (4) connect the battery negative cable. Check for battery voltage at the fused b(+) circuit cavity of the 12...

  • Page 548

    Be continuity. If ok, go to step 7. If not ok, replace the faulty push button switch. (7) unplug the liftglass release solenoid wire har- ness connector. Check for continuity between the ground circuit cavity of the wire harness connector and a good ground. There should be continuity. If ok, go to s...

  • Page 549

    Note: if a new door module is installed, the pro- grammable features must be enabled and/or dis- abled to the customer’s preferred settings. Use a drb scan tool and the proper body diagnostic pro- cedures manual to perform these operations. Power lock motor front door (1) remove the front door trim ...

  • Page 550

    (12) reverse the removal procedures to install. Tighten the power lock motor and latch screws to 10 n·m (95 in. Lbs.). Liftgate (1) disconnect and isolate the battery negative cable. (2) remove the screws that secure the liftgate lower trim panel to the liftgate (fig. 7). (3) using a wide flat-blade...

  • Page 551

    Vehicle theft/security systems contents page page general information arming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 disarming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 enabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 introduction . . . . . ....

  • Page 552

    Item on the drb scan tool for the procedures. Once this condition has been met, the pcm will allow the engine no-run feature to arm. Once the vtss engine no-run feature has been enabled, it cannot be disabled unless the pcm is replaced with a new unit. The same vtss engine no- run feature enable log...

  • Page 553

    Vehicle immobilizer system active disarming of the vehicle immobilizer system occurs when the unlock button of either of the two remote keyless entry (rke) transmitters is depressed, regardless of ignition switch position. This is the only way that the vehicle immobilizer system can be disarmed. Fol...

  • Page 554

    Door ajar switch the door ajar switches are mounted to the pillar in the rear of each door opening. They are plunger-type switches that are case grounded to the pillar. When the door is open the switch is closed, and when the door is closed the switch is open. The door ajar switches cannot be repair...

  • Page 555

    Set lamp the set lamp is a red light-emitting diode mounted with the auto headlamp ambient light sensor on top of the instrument panel near the driver side defroster outlet. The set lamp receives fused battery feed at all times and is grounded by the body control module to give a visible indication ...

  • Page 556

    (5) reverse the removal procedures to install. Tighten the switch mounting screw to 1.7 n·m (15 in. Lbs.). Door lock cylinder switch (1) disconnect and isolate the battery negative cable. (2) remove the bezel near the inside door latch release handle by inserting a straight-bladed screw- driver in t...

  • Page 557

    (8) reverse the removal procedures to install. Tighten the latch mounting screws to 7 n·m (62 in lbs.). Liftgate lock cylinder switch (1) disconnect and isolate the battery negative cable. (2) remove the screws that secure the liftgate lower trim panel to the liftgate (fig. 7). (3) using a wide flat...

  • Page 558

    (3) using a wide flat-bladed tool such as a trim stick, pry the trim panel away from the liftgate around the perimeter and remove the trim panel. Note: to aid in the removal of the trim panel, start at the bottom of the panel. (4) remove the two nuts that secure the liftglass latch to the liftgate i...

  • Page 559

    (6) unplug the headlamp or park lamp relay from the junction block. (7) install the headlamp or park lamp relay by aligning the relay terminals with the cavities in the junction block and pushing the relay firmly into place. (8) connect the battery negative cable. (9) test the relay operation. (10) ...

  • Page 561

    Vehicle theft/security systems contents page page general information arming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 disarming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 power-up mode . . . . . . . . ...

  • Page 562

    Still arm if the hood is open, but the engine compart- ment will not be protected. Once the 15 second arm- ing function is complete, the set lamp will flash at a slower rate to indicate that the vtss is armed. Disarming passive disarming of the vtss occurs when the vehicle is unlocked using the key ...

  • Page 563

    Liftgate ajar switch the liftgate ajar switch is integral to the liftgate latch assembly on the liftgate. It is a momentary- type switch that is open when the liftgate is closed, and closed when the liftgate is open. The liftgate ajar switch cannot be repaired and, if faulty or damaged, the liftgate...

  • Page 564

    Tion switch to the off position and using one of the following methods. (1) press the lock button on the rke transmit- ter. (2) lock the doors by pressing a power lock but- ton switch. (3) lock the driver or passenger door using the key. • the security light will flash, for about 16 sec- onds, indic...

  • Page 565

    Power-up mode when the vehicle immobilizer system senses that the vehicle battery has been disconnected and recon- nected, it enters its power-up mode. If the immobi- lizer system was armed prior to the battery disconnect, the system remains armed when the bat- tery is reconnected. If the immobilize...

  • Page 566

    Service procedures vehicle immobilizer system warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper pre- cautions could result i...

  • Page 567

    Removal and installation immobilizer receiver 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 i...

  • Page 568

    (3) pull the switch from the mounting hole in the door opening far enough to access the wire harness connector. (4) unplug the wire harness connector from the switch. (5) reverse the removal procedures to install. Tighten the switch mounting screw to 1.7 n·m (15 in. Lbs.). Door lock cylinder switch ...

  • Page 569

    Liftgate ajar switch (1) disconnect and isolate the battery negative cable. (2) remove the screws that secure the liftgate lower trim panel to the liftgate (fig. 7). (3) using a wide flat-bladed tool such as a trim stick, pry the trim panel away from the liftgate around the perimeter and remove the ...

  • Page 570

    (6) reverse the removal procedures to install. Liftglass ajar switch (1) disconnect and isolate the battery negative cable. (2) remove the screws that secure the liftgate lower trim panel to the liftgate (fig. 11). (3) using a wide flat-bladed tool such as a trim stick, pry the trim panel away from ...

  • Page 571

    (10) install the right cowl side trim and the fuse access panel. Horn relay (1) disconnect and isolate the battery negative cable. (2) remove the cover from the power distribution center (pdc) (fig. 14). (3) refer to the label on the pdc for horn relay identification and location. (4) unplug the hor...

  • Page 573: Power Seat Systems

    Power seat systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 memory system . . . . . . . . . . . . . . . . . . . . . . 1 description and operation circuit breaker . . . . . . . . . . . . . . . . . . . . . . 3 memory seat module . . . . . . ...

  • Page 574

    Description and operation memory seat module a memory seat module (msm), mounted under the inboard side of the driver side front seat cushion, is used on this model to control all of the driver side power seat memory functions and features. The msm contains a central processing unit and interfaces w...

  • Page 575

    Power lumbar adjuster and motor there is a reversible motor that operates the power lumbar adjuster. The motor is connected to a worm- drive gearbox that moves the lumbar adjuster mech- anism through a cable and lever-type actuator unit. When the power lumbar switch is actuated, a bat- tery feed and...

  • Page 576

    (2) remove the power seat switch as described in this group. Check for battery voltage at the fused b(+) circuit cavity of the switch wire harness connec- tor. If ok, go to step 3. If not ok, repair the open circuit to the junction block as required. (3) check for continuity between the ground cir- ...

  • Page 577

    (4) test the power seat switch as described in this group. If the switch tests ok, check the wire harness for the power recliner between the switch and the motor for shorts or opens. If the circuits check ok, replace the faulty power recliner adjuster and motor assembly. If the circuits are not ok, ...

  • Page 578

    (9) remove the three screws that secure the out- board seat cushion side shield to the seat cushion frame and pull the shield away from the seat cush- ion. (10) remove the four nuts that secure the upper seat adjuster mounting rails to the seat cushion frame. (11) unplug the wire harness connectors ...

  • Page 579

    (3) replace the seat back frame assembly, which includes the lumbar adjuster and motor (fig. 7). (4) reverse the removal procedures to install. Memory seat module (1) move the driver side power seat adjuster to the most raised and forward stop positions, if possible. (2) remove the single screw that...

  • Page 581: Power Window Systems

    Power window systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 power window system . . . . . . . . . . . . . . . . 1 description and operation body control module . . . . . . . . . . . . . . . . 2 circuit breaker . . . . . . . . . . . . . ....

  • Page 582

    Each power window switch, except the lockout switch, is illuminated by a light-emitting diode (led) when the ignition switch is turned to the on position. However, when the lockout switch is placed in the lock position, the led for the locked-out front and rear passenger door power window switches i...

  • Page 583

    Through these same two connections will cause the motor to rotate in the opposite direction. In addition, each power window motor is equipped with an integral self-resetting circuit breaker to pro- tect the motor from overloads. The power window motor and gearbox assembly cannot be repaired and, if ...

  • Page 584

    Senger side front or rear window that operates from the switch on that door, but does not operate from the master switch on the driver side front door, use a drb scan tool and the proper body diagnostic pro- cedures manual to diagnose the circuitry of the door modules and the ccd data bus. For circu...

  • Page 585

    (1) disconnect and isolate the battery negative cable. (2) remove the power window switch from the rear door trim panel as described in this group. (3) carefully unplug the power window switch from the wire harness connector. (4) check the switch continuity in each position, as shown in the chart (f...

  • Page 586

    Note: if a new door module is installed, the pro- grammable features must be enabled and/or dis- abled to the customer’s preferred settings. Use a drb scan tool and the proper body diagnostic pro- cedures manual to perform these operations. Power window switch (1) disconnect and isolate the battery ...

  • Page 587

    (4) slide the door glass rearward to remove it from the nuts. (5) pull the door glass to the full up position and tape the glass to the upper door window frame. (6) unplug the wire harness connector from the power window motor. (7) remove the four screws that secure the window regulator to the inner...

  • Page 588

    Possible and push down. Tighten the two loose win- dow regulator screws to 12 n·m (105 in. Lbs.). (13) attach the door glass by sliding the two nuts into the slotted holes on the regulator lift plate. Tighten the nuts to 12 n·m (105 in. Lbs.). (14) plug in the wire harness connector to the power win...

  • Page 589: Power Mirror Systems

    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 . . . . . . . . . . ...

  • Page 590

    Enhanced diagnostics, and allows the addition of many new feature capabilities. This group covers only the conventional diagnostic procedures for the power mirror system components. For diagnosis of the memory system, use of a drb scan tool and the proper body diagnostic procedures manual are recomm...

  • Page 591

    (1) check the circuit breaker in the junction block. If ok, go to step 2. If not ok, replace the faulty cir- cuit breaker. (2) check the fuse in the power distribution cen- ter (pdc). If ok, go to step 3. If not ok, replace the faulty fuse. (3) disconnect and isolate the battery negative cable. Remo...

  • Page 592

    Replace the faulty power mirror. If not ok, repair the circuits to the automatic day/night mirror as required. No mirror memory for diagnosis of the memory system, the use of a drb scan tool and the proper body diagnostic pro- cedures manual are recommended. Removal and installation door module (1) ...

  • Page 593

    Power mirror (1) disconnect and isolate the battery negative cable. (2) remove the front door trim panel as described under door module in this group. (3) unplug the electrochromic mirror wire harness connector, if equipped. (4) unclip the mirror wire harness(es) from the inner door panel. (5) remov...

  • Page 594

    Automatic day/night mirror index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 6 description and operation automatic day/night mirror . . . . . . . . . . . 6 diagnosis and testing automatic day/night mirror . . . . . . . . . . . 6 removal and installation...

  • Page 595

    (5) turn the ignition switch to the on position. Set the parking brake. Place the transmission gear selec- tor lever in the reverse position. Check for battery voltage at the backup lamp switch output circuit cav- ity of the mirror wire harness connector. If ok, plug in the mirror wire harness conne...

  • Page 597

    Chime/buzzer warning systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation body control module . . . . . . . . . . . . . . . . 1 driver door ajar switch . . . . . . . . . . . . . 2 driver seat belt switch . . . . . . ....

  • Page 598

    This group only covers the diagnosis and service of the hard-wired inputs used by the bcm to determine that a chime tone should be generated. For diagnosis of the bcm, the ccd data bus, or the other elec- tronic modules on the ccd data bus that send chime request messages to the bcm, refer to the pr...

  • Page 599

    Driver seat belt switch for circuit descriptions and diagrams, refer to 8w-45 - body control module in group 8w - wiring diagrams. Warning: on vehicles equipped with air- bags, refer to group 8m - passive restraint systems before attempting any steering wheel, steering column, or instrument panel co...

  • Page 600

    (1) disconnect and isolate the battery negative cable. Remove the outboard switch pod from the instrument panel. Refer to group 8e - instrument panel systems for the procedures. Unplug the head- lamp switch wire harness connector. Unplug the black 24-way wire harness connector from the body control ...

  • Page 601: Overhead Console Systems

    Overhead console systems contents page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 garage door opener storage bin . . . . . 2 reading and courtesy lamp . . . . . ...

  • Page 602

    The push button (step and u.S./metric) switch module in the overhead console is hard-wired to the trip computer. The compass flux-gate unit is integral to the trip computer, compass, and thermometer dis- play module unit. Data input for all other trip com- puter functions is received through ccd dat...

  • Page 603

    Door are selected and mounted on a post in the cen- ter of the storage bin door. The peg(s) selected and/or the post must be long enough to depress the button of the transmitter, when the garage door opener stor- age bin door is depressed. The pegs may be stacked, if necessary. Refer to the owner’s ...

  • Page 604

    And thermometer display module display. The sensor is mounted outside the passenger compartment near the front and center of the vehicle. If any portion of the ambient temperature sensor circuit fails, the thermometer display will self-diag- nose the circuit. An “sc” (short circuit) will appear in t...

  • Page 605

    Note: whenever the compass is calibrated manu- ally, the variation number must also be reset. See the compass variation adjustment procedure, in this group. Calibrate the compass manually as follows: (1) start the engine. If the compass/temperature data is not currently being displayed, momentarily ...

  • Page 606

    (6) place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header (fig. 2). The pur- pose of the paper is to protect the roof panel from scratches, and to define the area to...

  • Page 607

    Trip computer, compass, and thermometer display module (1) remove the overhead console as described in this group. (2) remove the screws that secure the trip com- puter, compass, and thermometer display module to the overhead console housing (fig. 5). (3) unplug the lighting and push button wire har...

  • Page 608

    Ambient temperature sensor (1) disconnect and isolate the battery negative cable. (2) remove the radiator grille unit. Refer to group 23 - body for the procedures. (3) locate the temperature sensor, on the radiator support behind the grille (fig. 6). (4) unplug the temperature sensor wire harness co...

  • Page 609: Wiring Diagrams

    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 chargin...

  • Page 611

    8w-01 general information index page page description and operation circuit identification . . . . . . . . . . . . . . . . . 3 connector/ground locations . . . . . . . . . 1 connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 3 electrostatic discharge (esd) sensitive devices . . . . . . ....

  • Page 612

    That may appear on the vehicle. For example, an up-to and after condition. Cautions are used to indicate information that could prevent making an error that may damage the vehicle. Warnings provide information to prevent per- sonal injury and vehicle damage. Below is a list of general warnings that ...

  • Page 613

    Circuit identification all circuits in the diagrams use an alpha/numeric code to identify the wire and its function (fig. 3). To identify which circuit code applies to a system, refer to the circuit identification code chart. This chart shows the main circuits only and does not show the secondary co...

  • Page 614

    Fig. 5 symbol identification 8w - 01 - 4 8w - 01 general information zg description and operation (continued).

  • Page 615

    Electrostatic discharge (esd) sensitive devices all esd sensitive components are solid state and a symbol (fig. 6) is used to indicate this. When han- dling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and ...

  • Page 616

    Troubleshooting tests before beginning any tests on a vehicles electrical system use the wiring diagrams and study the cir- cuit. Also refer to the troubleshooting wiring prob- lems section in this section. Testing for voltage (1) connect the ground lead of a voltmeter to a known good ground (fig. 8...

  • Page 617

    (3) analyze the symptoms. Use the wiring dia- grams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. (4) isolate the problem area. (5) repair the problem. (6) verify proper operation. For this step check for proper operation of...

  • Page 618

    (4) using special tool 6742 release the locking fin- gers on the terminal (fig. 13). (5) pull on the wire to remove it from the connec- tor. (6) repair or replace the connector or terminal, as necessary. Terminal/connector repair—thomas and betts connectors (1) disconnect battery. (2) disconnect the...

  • Page 619

    (4) position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (fig. 18) (fig. 19). (5) reset the terminal locking tang, if it has one. (6) insert the removed wire in the same cavity on the...

  • Page 620

    (3) remove connector locking wedge, if required (fig. 21). (4) position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (fig. 22) (fig. 23). (5) cut the wire 6 inches from the back of the...

  • Page 621

    (4) remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. (5) install the new diode in the harness, making sure current flow is correct. If necessary refer to the appropriate wiring diagram for current flow. (6) solder the connection together ...

  • Page 623

    8w-02 component index index page genernal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 component page a/c compressor clutch . . . . . . . . . . . . . . . . . 8w-42 a/c compressor clutch relay . . . . . . ....

  • Page 624

    Component page fuel sender unit . . . . . . . . . . . . . . . . . . . . . . 8w-30 fuses (jb) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8w-12 fuses (pdc) . . . . . . . . . . . . . . . . . . . . . . . . . . 8w-10 g switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8w-35 gauge ...

  • Page 625

    Component page splice information . . . . . . . . . . . . . . . . . . . . . 8w-70 steering wheel speed sensor . . . . . . . . . . . . . 8w-65 stop lamp switch . . . . . . . . . . . . . . . . . . . . . 8w-33 sunroof control module . . . . . . . . . . . . . . . . . 8w-64 sunroof switch . . . . . . . ....

  • Page 626

    8w-02 component index general information introduction this section provides an alphabetical listing of all the components covered in group 8w. For information on system operation, refer to the appropriate section of the wiring diagrams. 8w - 02 - 4 8w - 02 component index zg.

  • Page 627

    8w-10 power distribution index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 628

    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 ...

  • Page 629

    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/...

  • Page 630

    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 distrib...

  • Page 631

    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) zg ...

  • Page 632

    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 bat...

  • Page 633

    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 c23...

  • Page 634

    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) ...

  • Page 635

    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)...

  • Page 636

    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) 8w - 10 - 1...

  • Page 637

    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 rel...

  • Page 638

    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) 8w - 10 - 12 8w-10 power distribution ...

  • Page 639

    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 2...

  • Page 640

    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-...

  • Page 641

    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 solenoi...

  • Page 642

    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) ...

  • Page 643

    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 ...

  • Page 644

    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 controll...

  • Page 645

    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 ...

  • Page 646

    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 ...

  • Page 647

    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 f25...

  • Page 648

    Automatic shut down relay b18 a142 16dg/or b17 cav circuit function b16 f5 18rd/yl fused b(+) fused b(+) fused b(+) wiper park switch sense v6 16db function circuit cav c1 f86 16lg/rd* f86 16lg/rd** c2 c3 f86 16lg/rd relay wiper intermittent k900 20pk/wt b20 automatic shut down relay control c5 c4 v...

  • Page 649

    - - c9 c8 t141 14yl/td fused ignition switch output (st) t40 12lg/bk c7 cav circuit function c6 a1 12rd/wt fused b(+) engine starter motor relay output fuel pump relay output fused b(+) a61 16dg/bk function circuit cav c16 a64 16dg/wt f99 200r c17 c18 - relay pump fuel z4 20bk c10 park neutral posit...

  • Page 650

    8w-10 power distribution description and operation this section covers the power distribution center and all circuits involved with it. For additional infor- mation on system operation, refer to the appropriate wiring diagrams. 8w - 10 - 24 8w - 10 power distribution zg.

  • Page 651

    8w-12 junction block index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 652

    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...

  • Page 653

    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...

  • Page 654

    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) ...

  • Page 655

    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 i...

  • Page 656

    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 ...

  • Page 657

    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 doo...

  • Page 658

    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...

  • Page 659

    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...

  • Page 660

    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 ...

  • Page 661

    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...

  • Page 662

    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 ...

  • Page 663

    M1 20 pk a lamp vanity visor/ right left visor/ vanity lamp a m1 20 pk m1 20 pk dome/ reading lamp c 6 overhead console m1 20 pk s321 m1 20 pk d (8w-12-12) junction block from (8w-49-3) (8w-44-3) (8w-44-5) (8w-44-5) zg 8w-12 junction block 8w - 12 - 13 zg001212 j978w-3.

  • Page 664

    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) (...

  • Page 665

    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 informa...

  • Page 666

    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...

  • Page 667

    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 conn...

  • Page 668

    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 sea...

  • Page 669

    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 mo...

  • Page 670

    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) 8w - 12 - 20 8w-12 junction block zg j978w-3 zg001219.

  • Page 671

    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 ov...

  • Page 672

    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 ...

  • Page 673

    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) zg 8w-12...

  • Page 674

    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 la...

  • Page 675

    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 14...

  • Page 676

    20a feed circuit size circuit breaker 1* a31 12rd/bk 30a 87 l36 18lg rear fog lamp 86 l95 18dg/yl relay output l96 20lg/rd 85 cavity circuit function 30 f61 16wt/or fused b(+) internal 30 function circuit cav 85 z1 20bk ground fused ignition switch ouput (run) a31 rd/bk 86 87 fused ignition switch o...

  • Page 677

    C15 bk/wt rear window defogger relay output 87 86 a900 or/yl fused b(+) c14 wt/rd 85 cavity circuit function 30 a900 or/yl fused b(+) rear window defogger relay control fused b(+) ground function circuit - 87a - power antenna driver radio 12 volt output power antenna down control 5 4 3 2 1 cavity x1...

  • Page 678

    Cavity circuit function 30 m2 yl courtesy lamp relay output courtesy lamp relay control m112 br/lg 85 86 m1 pk fused b(+) 87 z1 bk ground - - 87a courtesy lamp relay (c) (d) relay lamp fog 87a - - fog lamp relay output l39 lb 87 fused b(+) f62 rd 86 85 l95 dg/yl fog lamp relay control fused b(+) f62...

  • Page 679

    8w-12 junction block description and operation this section covers the junction block and all cir- cuits involved with it. For additional information on system operation, please refer to the appropriate sec- tion of the wiring diagrams. Zg 8w - 12 junction block 8w - 12 - 29.

  • Page 681

    8w-15 ground distribution index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 682

    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-...

  • Page 683

    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...

  • Page 684

    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 1...

  • Page 685

    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 wash...

  • Page 686

    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 ...

  • Page 687

    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...

  • Page 688

    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...

  • Page 689

    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...

  • Page 690

    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 (8...

  • Page 691

    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 r...

  • Page 692

    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 c32...

  • Page 693

    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 lumb...

  • Page 694

    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) s...

  • Page 695

    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 dri...

  • Page 696

    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 courtes...

  • Page 697

    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 ...

  • Page 698

    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...

  • Page 699

    8w-15 ground distribution description and operation this section identifies the grounds, splices that connect to those grounds, and the components that connect those grounds. For additional information on system operation, refer to the appropriate section of the wiring diagrams. For an illustration ...

  • Page 701

    8w-20 charging system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 702

    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-7...

  • Page 703

    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 g10...

  • Page 704

    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 con...

  • Page 705

    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 ...

  • Page 706

    8w-20 charging system description and operation charging system the charging system is an integral part of the bat- tery and starting systems. Because all these systems work in conjunction, diagnose and test them together. Circuit a11 connects to the generator output termi- nal and the power distrib...

  • Page 707

    8w-21 starting system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 708

    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...

  • Page 709

    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 ...

  • Page 710

    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...

  • Page 711

    8w-21 starting system description and operation starting system circuit a0 from the battery is double crimped at the positive battery post. One branch of circuit a0 (battery positive cable) connects to the engine starter motor. The other a0 branch supplies voltage to the power distribution center (p...

  • Page 713

    8w-30 fuel/ignition systems index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 714

    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...

  • Page 715

    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 sole...

  • Page 716

    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/ pur...

  • Page 717

    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 d...

  • Page 718

    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 pow...

  • Page 719

    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...

  • Page 720

    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 sen...

  • Page 721

    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 sen...

  • Page 722

    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...

  • Page 723

    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...

  • Page 724

    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 in...

  • Page 725

    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 sen...

  • Page 726

    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 sig...

  • Page 727

    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 ...

  • Page 728

    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 fu...

  • Page 729

    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 a...

  • Page 730

    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/b...

  • Page 731

    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...

  • Page 732

    C1 a11 2 3 1 4 idle air control motor a19 c1 c1 a20 a10 c1 iac motor no. 3 driver driver no. 2 motor iac iac motor no. 1 driver driver no. 4 motor iac module control powertrain k40 16 br/wt k60 16 yl/bk k39 16 gy/rd k59 16 vt/bk no. 3 motor iac motor no. 2 iac no. 1 motor iac no. 4 motor iac 8w - 30...

  • Page 733

    C1 a11 3 2 4 1 idle air control motor a19 c1 c1 a20 a10 c1 iac motor no. 3 driver driver no. 2 motor iac iac motor no. 1 driver driver no. 4 motor iac module control powertrain k40 16 br/wt k60 16 yl/bk k39 16 gy/rd k59 16 vt/bk no. 3 motor iac motor no. 2 iac iac no. 1 motor no. 4 motor iac zg 8w-3...

  • Page 734

    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 (...

  • Page 735

    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 ...

  • Page 736

    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 ve...

  • Page 737

    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 (-) ...

  • Page 738

    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 m...

  • Page 739

    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...

  • Page 740

    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/d...

  • Page 741

    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/...

  • Page 742

    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/p...

  • Page 743

    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...

  • Page 744

    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 ...

  • Page 745

    8w-30 fuel/ignition systems index page page description and operation accelerator pedal position sensor (diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 automatic shut down (asd) relay . . . . . 34 automatic shut down relay (diesel) . . . 34 battery feed (diesel) . . . . . . . . ....

  • Page 746

    Pcm ground (diesel) ground for the powertrain control module (pcm) is supplied on the z12 circuit. This circuit connects to four cavities in the pcm and terminates at the pcm ground location. Data link connector circuit a250 from fuse 11 in the power distribu- tion center (pdc) powers circuit f75 th...

  • Page 747

    Fuel level sensor the fuel level sensor is a variable resistor. Circuit g40 provides the fuel level input to the powertrain control module (pcm). The pcm broadcasts fuel level data on the ccd bus. The micro-processor in the instrument cluster receives the message on the ccd bus, calculates fuel gaug...

  • Page 748

    • manifold absolute pressure sensor • oil pressure sensor • powertrain control module • throttle position sensor • transmission solenoid assembly • upstream heated oxygen sensor • vehicle speed control switch • vehicle speed sensor crankshaft position sensor (diesel) the powertrain control module (p...

  • Page 749

    Circuit k22 delivers the tps signal to the pcm. Circuit k22 connects to cavity a23 of the pcm. The pcm provides a ground for the throttle posi- tion sensor signal (circuit k22) through circuit k4. Circuit k4 connects to cavity a4 of the pcm. Helpful information refer to group 14 for throttle positio...

  • Page 750

    • transmission solenoid assembly • upstream heated oxygen sensor • vehicle speed control switch • vehicle speed sensor oil pressure sensor the oil pressure sensor is a variable resistor. A change in engine oil pressure changes the resistance in the sending unit which alters the signal sensed by the ...

  • Page 751

    Fuel quantity actuator power for the fuel quantity actuator is supplied on circuit a142. This circuit is hot when the contacts in the diesel powertrain control module (pcm) relay are closed. Ground for the actuator is controlled by the pcm on circuit k140. Fuel heater (diesel) when the ignition swit...

  • Page 753

    8w-31 transmission control system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 754

    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 converte...

  • Page 755

    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 pow...

  • Page 756

    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...

  • Page 757

    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 lam...

  • Page 758

    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/...

  • Page 759

    8w-31 transmission control system index page page description and operation governor pressure sensor . . . . . . . . . . . 7 output shaft speed sensor . . . . . . . . . . . 7 overdrive switch . . . . . . . . . . . . . . . . . . . . . 7 shift interlock . . . . . . . . . . . . . . . . . . . . . . . 7 ...

  • Page 760

    B29 of the pcm. Circuit k6 from cavity b31 of the pcm supplies 5 volts to the sensor. The pcm pro- vides ground for the govenor pressure sensor on cir- cuit k4. Circuit k4 connects to cavity a4 of the pcm. The governor pressure sensor is part of the trans- mission solenoid assembly. Transmission tem...

  • Page 761

    8w-33 vehicle speed control index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 762

    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/l...

  • Page 763

    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 v...

  • Page 764

    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 ...

  • Page 765

    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 ...

  • Page 766

    8w-33 vehicle speed control description and operation vehicle speed control the powertrain control module (pcm) operates the vehicle speed control system. The vehicle speed control switches are located in the steering wheel. Circuit v32 from cavity c11 of the pcm connects to circuit v30 through the ...

  • Page 767

    8w-35 all-wheel anti-lock brakes index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 768

    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 (+) jun...

  • Page 769

    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 switc...

  • Page 770

    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 whe...

  • Page 771

    8w-35 all-wheel anti-lock brakes index page page description and operation abs warning lamp . . . . . . . . . . . . . . . . . . . . . 5 data link connector . . . . . . . . . . . . . . . . . . 5 g-switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 introduction . . . . . . . . . . . . ...

  • Page 773

    8w-39 vehicle theft security system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 774

    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/b...

  • Page 775

    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...

  • Page 776

    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 ground ground ground 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 g...

  • Page 777

    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...

  • Page 778

    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 ...

  • Page 779

    8w-39 vehicle theft security system index page page description and operation introduction . . . . . . . . . . . . . . . . . . . . . . . . . 7 vehicle theft security system operation . . . . . . . . . . . . . . . . . . . . . . . . . . 7 description and operation introduction the body control module ...

  • Page 781

    8w-40 instrument cluster index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 782

    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 inst...

  • Page 783

    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...

  • Page 784

    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...

  • Page 785

    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 c...

  • Page 786

    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) 8w - 40 - 6 8w-4...

  • Page 787

    8w-40 instrument cluster index page page description and operation abs warning lamp . . . . . . . . . . . . . . . . . . . . . 7 engine coolant temperature gauge . . . 7 fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 high beam indicator lamp . . . . . . . . . . . . . . 8 illuminat...

  • Page 788

    Powertrain control module (pcm) transmits the data over the ccd bus. High beam indicator lamp the micro-processor in the instrument cluster switches the high beam indicator lamp on and off through a transistor in lamps ground circuit. The body control module (bcm) signals the instrument cluster micr...

  • Page 789

    8w-41 horn/cigar lighter index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 790

    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 ...

  • Page 791

    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...

  • Page 792

    8w-41 horn/cigar lighter description and operation horn the horn system is powered by circuit f31 from fuse 6 in the power distribution center (pdc). Cir- cuit f31 supplies voltage to the coil and contact sides of the horn relay in the pdc. When the operator presses the horn switch, a ground path is...

  • Page 793

    8w-42 air conditioning/heater index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 794

    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...

  • Page 795

    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 aut...

  • Page 796

    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 con...

  • Page 797

    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 ...

  • Page 798

    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 c...

  • Page 799

    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...

  • Page 800

    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 b...

  • Page 801

    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...

  • Page 802

    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 comp...

  • Page 803

    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 1...

  • Page 804

    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 ...

  • Page 805

    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) zg 8w-42 air conditioning-heater...

  • Page 806

    8w-42 air conditioning/heater index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 14 description and operation a/c operation—automatic temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 a/c operation—manual a/c . . . . . . . . . ...

  • Page 807

    Module (bcm) receives the a/c select signal on cir- cuit c90. After receiving the input, the bcm signals the powertrain control module (pcm) on the ccd bus. The a/c low pressure and high pressure switches are wired in series and connect to ground on circuit z1. Circuit c3 from the pcm connects to th...

  • Page 808

    Pressure switch connects circuit c21 to ground cir- cuit z1. If the a/c low pressure and high pressure switches are closed, the pcm senses the a/c request signal on circuit c3. After sensing the a/c request signal, the pcm sup- plies ground for the coil side of a/c compressor clutch relay on circuit...

  • Page 809

    8w-43 airbag system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 810

    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 pa...

  • Page 811

    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/...

  • Page 812

    8w-43 airbag system index page page description and operation airbag impact sensor . . . . . . . . . . . . . . . . . 4 airbag squib (airbag igniter) . . . . . . . . . . 4 airbag warning lamp . . . . . . . . . . . . . . . . . . 4 introduction . . . . . . . . . . . . . . . . . . . . . . . . . 4 descri...

  • Page 813

    8w-44 interior lighting index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 814

    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 ...

  • Page 815

    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-...

  • Page 816

    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-12-1...

  • Page 817

    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...

  • Page 818

    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/ ...

  • Page 819

    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) zg 8w-44 interior lighting 8w - 44 - 7 zg004406 j978w-3 position neutral park/ switch 1 3 switch position ...

  • Page 820

    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 ampli...

  • Page 821

    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...

  • Page 822

    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...

  • Page 823

    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 1...

  • Page 824

    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 autom...

  • Page 825

    3 0 1 2 3 auto 2 park 1 head 0 off switch headlamp panel lamp dimmer switch signal panel lamp driver body control module 2 z1 16 bk z1 14 bk z1 14 bk e2 20 or 707 20 bk/wt g304 s202 2 c301 e2 20 or 20 c2 16 c2 1 8 s209 lamps illumination batt a6 15a fuse 17 11 c9 366 16 pk/or 15 junction block zg 8w...

  • Page 826

    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 aj...

  • Page 827

    8w-44 interior lighting index page page description and operation courtesy lamps, cargo lamp, ignition switch key-in halo lamp . . . . . . . . . . . . . 15 day/night mirror . . . . . . . . . . . . . . . . . . . . . 16 glove box lamp . . . . . . . . . . . . . . . . . . . . . . 16 illumination lamps ....

  • Page 828

    Liftgate courtesy lamp disable switch when closed, the liftgate disable switch provides signal to the bcm on circuit m4 indicating a request to disable the courtesy lamps. To operate, all the doors must be closed with only the liftgate open. Pushing on the liftgate lens activates the switch. Pushing...

  • Page 829

    8w-45 body control module index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 830

    3 fuse 10a run-acc a31 block junction a16 a15 15a fuse 18 v23 20 br/pk c1 16 c1 18 f99 18 or f99 20 or f99 20 or s101 h8 c236 body control module 15 c2 fused ign. (run-acc) (run-st) ign. Fused 8 c3 c2 24 ground ground ground g304 s302 z2 20 bk/or z2 18 bk/or z2 18 bk/or z2 18 bk/or z2 18 bk/or z1 16...

  • Page 831

    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 ...

  • Page 832

    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...

  • Page 833

    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 contro...

  • Page 834

    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 contr...

  • Page 835

    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 1...

  • Page 836

    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...

  • Page 837

    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 au...

  • Page 838

    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 h...

  • Page 839

    S329 g78 20 tn/bk 3 c325 1 2 switch ajar liftgate liftglass 1 switch ajar 2 a (8w-45-10) c321 from g78 tn/bk 20 tn/bk g78 20 20 g78 tn/bk rear wiper module 6 z1 bk 20 12 bk z1 20 bk z1 bk 12 z1 s328 12 bk z1 g300 s328 2 (8w-15-11) (8w-15-10) (8w-53-4) zg 8w-45 body control module 8w - 45 - 11 zg0045...

  • Page 840

    8w-45 body control module index page page description and operation a/c select switch . . . . . . . . . . . . . . . . . . . . 12 ajar chime . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ambient temperature sensor . . . . . . . . . 12 auto headlamps . . . . . . . . . . . . . . . . . . . . ...

  • Page 841

    Liftgate courtesy lamp disable switch when the courtesy lamp disable switch closes, it provides battery voltage to the body control module (bcm) on circuit m4. Auto headlamps when the operator puts the headlamp switch in the auto position, the auto headlamp switch closes and connects circuit l24 fro...

  • Page 843

    8w-46 message center index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 844

    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 b...

  • Page 845

    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/o...

  • Page 846

    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 b...

  • Page 847

    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/o...

  • Page 848

    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 z...

  • Page 849

    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 ...

  • Page 850

    8w-46 message center index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . . 8 description and operation graphic display module . . . . . . . . . . . . . . . 8 vehicle information center . . . . . . . . . . . 8 general information introduction each four-whe...

  • Page 851

    When the transfer case switch is in part time 4wd position, it connects circuit t107 from the vic to ground on circuit z12. In addition to illuminating the 4wd display, the vic also illuminates the part time display. When the transfer case switch is in full time 4wd position, it connects circuit t10...

  • Page 853

    8w-47 audio system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 854

    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 ...

  • Page 855

    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...

  • Page 856

    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 ...

  • Page 857

    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 le...

  • Page 858

    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 ...

  • Page 859

    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 ri...

  • Page 860

    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/...

  • Page 861

    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 ...

  • Page 862

    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...

  • Page 863

    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 rea...

  • Page 864

    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 ...

  • Page 865

    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.

  • Page 866

    8w-47 audio system index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 14 description and operation amplifier and speakers—premium . . . . . 14 limited plus system . . . . . . . . . . . . . . . . . . 15 power antenna—export only . . . . . . . . . 15 radio...

  • Page 867

    To the left instrument panel speaker and left front door speaker. Circuit x85 is the return from speakers to the amplifier and circuit x55 is the return from the amplifier to the radio. Circuits x87 and x85 from the amplifier connect to circuits x55 and x53 at the jumper harness for the left front d...

  • Page 869

    8w-48 rear window defogger index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 870

    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 1...

  • Page 871

    8w-48 rear window defogger description and operation rear window defogger the body control module (bcm) operates the rear window defogger system through a relay located in the junction block. When the operator presses the rear window defogger switch, the switch connects cir- cuit c80 from the bcm to...

  • Page 873

    8w-49 overhead console index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 874

    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 2...

  • Page 875

    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...

  • Page 876

    8w-49 overhead console description and operation overhead console when the ignition switch is in the run position, it connects circuit a1 from fuse 8 in the power distri- bution center (pdc) to circuit a22. Circuit a22 pow- ers circuit f83 through fuse 6 in the junction block. Circuit f83 supplies p...

  • Page 877

    8w-50 front lighting index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 878

    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 l...

  • Page 879

    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...

  • Page 880

    1 brake warning switch 2 c304 s303 g9 20 gy/bk g9 18 gy/bk switch brake park g9 20 gy/bk module control body c3 2 brake switch sense (8w-45-9) (8w-40-6) 8w - 50 - 4 8w-50 front lighting zg j978w-3 zg005003.

  • Page 881

    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 sen...

  • Page 882

    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 rig...

  • Page 883

    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 sens...

  • Page 884

    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 l9...

  • Page 885

    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/ tu...

  • Page 886

    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 ...

  • Page 887

    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 ...

  • Page 888

    8w-50 front lighting index page page description and operation auto headlamps . . . . . . . . . . . . . . . . . . . . . 12 fog lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 headlamp leveling . . . . . . . . . . . . . . . . . . . 12 headlamps . . . . . . . . . . . . . . . . . . . . ....

  • Page 889

    Lamp high beam operation on circuit l3, it energizes the fog lamp relay. The bcm energizes the relay by grounding the relay coil on circuit l95. Circuit f62 from fuse 19 in the power distribution center (pdc) powers the relay coil and contacts. When the fog lamp relay energizes, it connects cir- cui...

  • Page 891

    8w-51 rear lighting index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 892

    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...

  • Page 893

    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 l...

  • Page 894

    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 ...

  • Page 895

    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 n...

  • Page 896

    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/...

  • Page 897

    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 m...

  • Page 898

    8w-51 rear lighting description and operation tail lamps, rear license plate lamps and side marker lamps circuit a6 from fuse 13 in the power distribution center (pdc) feeds circuit 366 through fuse 17 in the junction block. Circuit 366 connects to the headlamp switch. When the headlamp switch is in...

  • Page 899

    8w-52 turn signals index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 900

    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...

  • Page 901

    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 1...

  • Page 902

    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 hazar...

  • Page 903

    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...

  • Page 904

    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 c3...

  • Page 905

    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...

  • Page 906

    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 d...

  • Page 907

    8w-52 turn signals description and operation electronic flasher relay the electronic flasher relay in the junction block supplies battery voltage to the turn signal/hazard switch circuitry in the multi-function switch. When the ignition switch is off, the hazard flashers will operate but the turn si...

  • Page 909

    8w-53 wipers index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 910

    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 windshie...

  • Page 911

    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...

  • Page 912

    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 v...

  • Page 913

    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 info...

  • Page 914

    8w-53 wipers description and operation intermittent wiper operation in the accessory or run position, the ignition switch connects circuit a1 from fuse 8 in the pdc to circuit a31. Circuit a31 powers circuit f86 through the circuit breaker in cavity 1 of the junction block. Circuit f86 supplies powe...

  • Page 915

    8w-54 trailer tow index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 916

    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 ...

  • Page 917

    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...

  • Page 918

    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 1...

  • Page 919

    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 sw...

  • Page 920

    8w-54 trailer tow general information introduction two trailer tow packages are available; a factory installed package and a package with after-market provisions. This section provides separate wiring dia- grams for each. Description and operation trailer tow—factory installed the factory installed ...

  • Page 921

    8w-60 power windows index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 922

    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 ...

  • Page 923

    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 ...

  • Page 924

    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...

  • Page 925

    8w-60 power windows index page page description and operation introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5 power windows . . . . . . . . . . . . . . . . . . . . . . 5 description and operation introduction all four power windows can be controlled by the switches on the drivers do...

  • Page 926

    For window up operation the circuits are reversed. The ddm powers circuit q17 and grounds circuit q27. Right rear window circuits q18 and q28 connect the passenger’s door module (pdm) to the right rear window switch. When the operator has not selected the window lock- out feature, the pdm connects c...

  • Page 927

    8w-61 power door locks index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 928

    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 ...

  • Page 929

    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...

  • Page 930

    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 ...

  • Page 931

    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...

  • Page 932

    8w-61 power door locks description and operation introduction the drivers door module (ddm) powers the driv- ers door lock motor. The passengers door module (pdm) powers the passenger, both rear doorlock and the liftgate lock motors. The ddm and pdm each contain a door lock switch. When one of the s...

  • Page 933

    8w-62 power mirrors index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 934

    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 c...

  • Page 935

    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 ...

  • Page 936

    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...

  • Page 937

    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 ...

  • Page 938

    8w-62 power mirrors description and operation introduction the drivers door module (ddm) controls both power mirrors. The ddm adjusts the left mirror and signals the passenger door module (pdm) over the ccd bus to adjust the right mirror. A push button switch on the outside of the ddm controls the h...

  • Page 939

    8w-63 power seat index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 940

    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 junct...

  • Page 941

    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-...

  • Page 942

    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-1...

  • Page 943

    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)...

  • Page 944

    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 ...

  • Page 945

    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 mod...

  • Page 946

    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 ...

  • Page 947

    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 s3...

  • Page 948

    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 ...

  • Page 949

    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 ...

  • Page 950

    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/b...

  • Page 951

    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 c...

  • Page 952

    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 ...

  • Page 953

    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 switche...

  • Page 954

    8w-63 power seat index page page description and operation heated seats . . . . . . . . . . . . . . . . . . . . . . . . 17 introduction . . . . . . . . . . . . . . . . . . . . . . . . 16 memory seats . . . . . . . . . . . . . . . . . . . . . . . 17 power seats . . . . . . . . . . . . . . . . . . . ....

  • Page 955

    A bus bar internal to the switch connects circuit p12 to ground on circuit z1. For rear vertical down function the circuits are reversed. P12 is the feed, and p10 is the ground. When the operator selects the front vertical up function, the switch passes power from circuit f35 to circuit p18. Circuit...

  • Page 956

    When the ignition switch is in the run position, it connects circuit a1 from fuse 8 in the pdc to circuit a22. Circuit a22 powers circuit f71 through fuse 12 in the junction block. Circuit f71 splices to supply power to the driver and passenger heated seat switches and provides an input to the heate...

  • Page 957

    8w-64 power sunroof index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 958

    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...

  • Page 959

    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 zg...

  • Page 960

    8w-64 power sunroof index page description and operation power sunroof . . . . . . . . . . . . . . . . . . . . . . 4 description and operation power sunroof when the ignition switch is in the accessory or run position it connects circuit a1 from fuse 8 in the power distribution center (pdc) to circu...

  • Page 961

    8w-65 speed proportional steering index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 962

    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...

  • Page 963

    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 pro...

  • Page 964

    8w-65 speed proportional steering index page page description and operation data link connector . . . . . . . . . . . . . . . . . . 4 introduction . . . . . . . . . . . . . . . . . . . . . . . . . 4 speed proportional steering control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 965

    8w-70 splice information index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 component page s100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8w-10-16 s101 . . . . . . . . . . . ...

  • Page 966

    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 p...

  • Page 967

    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 sens...

  • Page 968

    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...

  • Page 969

    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 1...

  • Page 970

    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 j...

  • Page 971

    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 a14...

  • Page 972

    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 ...

  • Page 973

    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...

  • Page 975

    8w-80 connector pin-outs index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 component page a/c heater control - c1 . . . . . . . . . . . . . . . .8w-80-5 a/c heater control - c2 . . . . . . . . . ...

  • Page 976

    Component page dome/reading lamp . . . . . . . . . . . . . . . . . .8w-80-29 downstream heated oxygen sensor . . . . . .8w-80-29 driver door module - c1 . . . . . . . . . . . . . . .8w-80-29 driver door module - c2 . . . . . . . . . . . . . . .8w-80-29 driver door module - c3 . . . . . . . . . . . ....

  • Page 977

    Component page left rear fog lamp . . . . . . . . . . . . . . . . . .8w-80-51 left rear power window motor. . . . . . . . . .8w-80-52 left rear power window switch . . . . . . . . .8w-80-52 left rear side marker lamp. . . . . . . . . . . .8w-80-52 left rear turn signal lamp . . . . . . . . . . . .8w...

  • Page 978

    Component page underhood lamp. . . . . . . . . . . . . . . . . . . . .8w-80-79 upstream heated oxygen sensor . . . . . . . .8w-80-79 vehicle information center . . . . . . . . . . . . .8w-80-80 vehicle speed control servo . . . . . . . . . . . .8w-80-80 vehicle speed control/horn switch . . . . . . ...

  • Page 979

    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 fused ignition switch output (run) a/c select input cav 1 2 3 4 5 6 7 a/c-heater control - c2 black 6 ...

  • Page 980

    8w - 80 - 6 zg 8w-80 connector pin-outs j978w-3 zg008006 airbag control module black circuit - - - - - - - - - - - - - function - - - - - - - - - - - - - driver airbag line 2 driver airbag line 1 passenger airbag line 1 passenger airbag line 2 ground fused ignition switch output (run/start) ccd bus ...

  • Page 981

    8w - 80 - 7 zg 8w-80 connector pin-outs 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 ignition switch ou...

  • Page 982

    8w - 80 - 8 zg 8w-80 connector pin-outs j978w-3 zg008008 circuit - function - 5 volt supply blend air door feedback signal sensor return blend air door motor driver blend air door motor driver cav 1 2 3 4 5 6 c40 20dg/yl c36 20db/rd d41 20lg/wt c35 20db/wt c34 20vt/wt blend door actuator (with autom...

  • Page 983

    8w - 80 - 9 zg 8w-80 connector pin-outs j978w-3 zg008009 circuit - - - - - - - function - - - - - - - windshield wiper switch signal sensor return ambient temperature sensor signal switched courtesy lamp feed auto headlamp switch sense rear window defogger switch sense dimmer switch low beam output ...

  • Page 984

    8w - 80 - 10 zg 8w-80 connector pin-outs j978w-3 zg008010 circuit - - - - - function - - - - - ultralight sensor driver radio control mux wiper park switch sense courtesy lamp relay control a/c select input fused b(+) ultralight sensor signal auto headlamp relay control horn relay control rear windo...

  • Page 985

    8w - 80 - 11 zg 8w-80 connector pin-outs j978w-3 zg008011 circuit function red brake warning lamp driver red brake warning lamp driver cav 1 2 g9 16gy/bk g9 16gy/bk brake warning switch black 2 1 c102 circuit cav 1 2 3 1 2 3 black circuit cav 1 2 3 l65 18lg/db l90 18db/rd z1 18bk l65 18lg/db l90 18d...

  • Page 986

    8w - 80 - 12 zg 8w-80 connector pin-outs 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...

  • Page 987

    8w - 80 - 13 zg 8w-80 connector pin-outs 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/...

  • Page 988

    8w - 80 - 14 zg 8w-80 connector pin-outs 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...

  • Page 989

    8w - 80 - 15 zg 8w-80 connector pin-outs 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 ...

  • Page 990

    8w - 80 - 16 zg 8w-80 connector pin-outs 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/l...

  • Page 991

    8w - 80 - 17 zg 8w-80 connector pin-outs 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 h...

  • Page 992

    8w - 80 - 18 zg 8w-80 connector pin-outs 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 ...

  • Page 993

    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...

  • Page 994

    8w - 80 - 20 zg 8w-80 connector pin-outs 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 ...

  • Page 995

    8w - 80 - 21 zg 8w-80 connector pin-outs 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 c3...

  • Page 996

    8w - 80 - 22 zg 8w-80 connector pin-outs 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...

  • Page 997

    8w - 80 - 23 zg 8w-80 connector pin-outs 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...

  • Page 998

    8w - 80 - 24 zg 8w-80 connector pin-outs 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...

  • Page 999

    8w - 80 - 25 zg 8w-80 connector pin-outs 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 ...

  • Page 1000

    8w - 80 - 26 zg 8w-80 connector pin-outs 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 courtesy lamp relay output fused b(+) liftgate cour...

  • Page 1001

    8w - 80 - 27 zg 8w-80 connector pin-outs 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 stop lamp switch output stop lamp switch output ground ground ca...

  • Page 1002

    8w - 80 - 28 zg 8w-80 connector pin-outs 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...

  • Page 1003

    8w - 80 - 29 zg 8w-80 connector pin-outs j978w-3 zg008029 circuit function ground courtesy lamp relay output fused b(+) cav a b c z1 20bk m2 2oyl m1 20pk dome/reading lamp natural a c circuit function automatic shut down relay output ground sensor ground downstream heated oxygen sensor signal cav 1 ...

  • Page 1004

    8w - 80 - 30 zg 8w-80 connector pin-outs 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 h...

  • Page 1005

    8w - 80 - 31 zg 8w-80 connector pin-outs 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 horiz...

  • Page 1006

    8w - 80 - 32 zg 8w-80 connector pin-outs j978w-3 zg008032 circuit function lumbar rearward switch sense lumbar forward driver ground fused b(+) ground lumbar forward switch sense lumbar forward switch sense lumbar reward driver cav 1 1 2 3 4 5 5 p104 20yl/rd* p107 18or/bk z1 18bk f35 18rd z1 18bk p1...

  • Page 1007

    8w - 80 - 33 zg 8w-80 connector pin-outs j978w-3 zg008033 circuit function 6 volt sensor supply horizontal position sense sensor ground cav a b c p29 20br/wt p47 20lb p28 20br/rd black driver power seat recliner motor sensor c a circuit function ground recliner up switch sense recliner up driver hor...

  • Page 1008

    8w - 80 - 34 zg 8w-80 connector pin-outs j978w-3 zg008034 2 1 driver side airbag yellow circuit function driver air bag line 2 driver air bag line 1 cav 1 2 r45 18dg/lb r43 18bk/lb circuit function ignition switch output (start/run) evaporative emission solenoid control cav 1 2 f99 20or k52 18pk/bk ...

  • Page 1009

    8w - 80 - 35 zg 8w-80 connector pin-outs j978w-3 zg008035 * gas ** diesel circuit function b(+) b(+) engine starter motor relay output engine starter motor relay output cav 1 1 2 2 a0 6rd a0 2rd** t40 12lg/bk t40 14lg/bk** engine starter motor black 1 2 circuit - function - fused ignition switch out...

  • Page 1010

    8w - 80 - 36 zg 8w-80 connector pin-outs 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 auto s...

  • Page 1011

    8w - 80 - 37 zg 8w-80 connector pin-outs j978w-3 zg008037 circuit function g switch ground g switch no. 1 sense g switch no. 2 sense cav 1 2 3 b43 20pk/or b41 20yl/vt b42 20tn/wt g-switch circuit - function - automatic shut down relay output generator field driver cav 1 2 3 a142 16dg/or k20 18dg/yl ...

  • Page 1012

    1 2 3 4 5 6 7 8 8w - 80 - 38 zg 8w-80 connector pin-outs 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 park lamp relay output washer fluid level sense 4-wheel driv...

  • Page 1013

    8w - 80 - 39 zg 8w-80 connector pin-outs j978w-3 zg008039 circuit - - - function - - - panel lamp driver ground switched courtesy lamp feed fog lamp relay output ground fog lamp switch output coil driver #6 panel lamp dimmer switch signal fused b(+) low headlamp switch sense auto headlamp switch sen...

  • Page 1014

    8w - 80 - 40 zg 8w-80 connector pin-outs j978w-3 zg008040 circuit function idle air control no. 1 driver idle air control no. 3 driver idle air control no. 4 driver idle air control no. 2 driver cav 1 2 3 4 k39 16gy/rd k40 16br/wt k59 16vt/bk k60 16yl/bk idle air control motor (5.2l v-8) black 4 1 c...

  • Page 1015

    8w - 80 - 41 zg 8w-80 connector pin-outs j978w-3 zg008041 circuit function automatic shut down relay output injector no.1 driver cav 1 2 a142 18dg/or k11 18wt/db circuit function automatic shut down relay output injector no. 2 driver cav 1 2 a142 18dg/or k12 18tn gray 2 fuel injector no.1 1 gray 2 f...

  • Page 1016

    8w - 80 - 42 zg 8w-80 connector pin-outs j978w-3 zg008042 circuit function automatic shut down relay output injector no. 6 driver cav 1 2 a142 18dg/or k58 18br/yl gray 2 fuel injector no.6 1 circuit function automatic shut down relay output injector no. 7 driver cav 1 2 a142 18dg/or k17 18db/wt gray...

  • Page 1017

    8w - 80 - 43 zg 8w-80 connector pin-outs j978w-3 zg008043 junction block - c3 circuit - - - - function - - - - horn relay control 2-wheel drive lamp/low range fog lamp relay output fused b(+) fused b(+) park lamp switch output turn signal switch output fused ignition switch output (acc/run) cav 1 2 ...

  • Page 1018

    8w - 80 - 44 zg 8w-80 connector pin-outs j978w-3 zg008044 junction block - c6 3 1 4 2 black circuit function fused ignition switch output (acc/run) fused ignition switch output (start/run) rear window defogger relay output fused b(+) cav 1 2 3 4 a31 12rd/bk a21 12db/gy c15 12bk/wt f61 16wt/or juncti...

  • Page 1019

    8w - 80 - 45 zg 8w-80 connector pin-outs j978w-3 zg008045 8 3 1 12 7 2 junction block - c9 light gray circuit - - - function - - - rear window defogger lamp driver fused b(+) fused ignition switch output (run) fused b(+) fused ignition switch output (start/run) fused ignition switch output (run) fus...

  • Page 1020

    8w - 80 - 46 zg 8w-80 connector pin-outs j978w-3 zg008046 black 1 3 6 7 10 2 junction block body connector - c14 circuit - - function - - back-up lamp switch output fused ignition switch output (start/run) courtesy lamp relay output radio 12 volt output fused b(+) fused b(+) fused b(+) fused b(+) ca...

  • Page 1021

    8w - 80 - 47 zg 8w-80 connector pin-outs j978w-3 zg008047 circuit - function - not used not used stop lamp switch output park lamp relay output park lamp relay output park lamp switch output park lamp switch output stop lamp switch output stop lamp switch output stop lamp switch output ground cav 1 ...

  • Page 1022

    8w - 80 - 48 zg 8w-80 connector pin-outs j978w-3 zg008048 circuit function back-up lamp switch output ground cav a g l10 18br/lg z1 18bk black left back-up lamp a g circuit function fused b(+) courtesy lamp relay output cav a b m1 20pk m2 20yl left courtesy lamp black circuit function fused b(+) gro...

  • Page 1023

    8w - 80 - 49 zg 8w-80 connector pin-outs j978w-3 zg008049 circuit function left front door unlock driver left front door lock driver cav 1 2 p34 18pk/bk p35 18or/vt black 2 1 left front door lock motor circuit function left front (+) left front (-) cav a b x53 20dg x55 20br/rd b left front door spea...

  • Page 1024

    8w - 80 - 50 zg 8w-80 connector pin-outs j978w-3 zg008050 black left front turn signal lamp a g circuit function turn signal switch output ground cav a g l64 18tn/db z1 18bk circuit function left front wheel speed sensor (-) left front wheel speed sensor (+) cav 1 2 b8 20rd/db b9 20rd left front whe...

  • Page 1025

    8w - 80 - 51 zg 8w-80 connector pin-outs j978w-3 zg008051 circuit function park lamp relay output ground cav 1 2 l90 20db/rd z1 20bk natural left license lamp 1 2 circuit function park lamp relay ground cav 1 2 l90 18db/rd z1 18bk left park lamp circuit function door unlock driver door lock driver c...

  • Page 1026

    8w - 80 - 52 zg 8w-80 connector pin-outs j978w-3 zg008052 circuit function left rear window driver (up) left rear window driver (up) left rear door switch illumination left rear window driver (down) left rear window driver (down) ground cav 1 2 3 4 5 6 q18 16gy/bk q12 16br e20 20or/dg q28 16dg/wt q2...

  • Page 1027

    8w - 80 - 53 zg 8w-80 connector pin-outs j978w-3 zg008053 circuit function stop lamp switch output park lamp switch output ground cav a b g l74 18pk/bk l21 18lb/wt z1 18bk black b a g left tail/stop lamp circuit function fused b(+) ground cav a b m1 20pk z1 20bk a left visor/ vanity mirror black b c...

  • Page 1028

    8w - 80 - 54 zg 8w-80 connector pin-outs j978w-3 zg008054 circuit - function - ground liftglass ajar switch sense cav 1 2 3 z1 20bk g78 20tn/bk 1 liftglass ajar switch black 3 circuit function fused b(+) liftglass limit switch output cav a b f70 16pk/bk p101 16or/pk a liftglass limit switch natural ...

  • Page 1029

    8w - 80 - 55 zg 8w-80 connector pin-outs 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 fuel quantity actuator ground...

  • Page 1030

    8w - 80 -56 zg 8w-80 connector pin-outs j978w-3 zg008056 circuit - function - 6 volt sensor supply sensor ground horizontal position sense front riser position sense rear riser position sense recliner position sense lumbar position sense front riser down switch sense front riser up switch sense rear...

  • Page 1031

    8w - 80 - 57 zg 8w-80 connector pin-outs j978w-3 zg008057 circuit function fused ignition switch output (run) ground ccd bus(+) courtesy lamp relay output ccd bus(-) fused b(+) cav 1 2 3 4 5 6 f83 20yl/dg z1 20bk d1 18vt/br m2 20yl d2 18wt/bk m1 20pk mini overhead console red 3 4 1 6 circuit functio...

  • Page 1032

    8w - 80 - 58 zg 8w-80 connector pin-outs j978w-3 zg008058 circuit function sensor ground oil pressure sensor signal oil pressure sensor signal sensor return cav 1 1 2 2 k4 20bk/lb g60 20gy/yl* g6 18gy/wt k167 20br/yl* black oil pressure sensor 2 1 circuit function output shaft speed sensor signal (+...

  • Page 1033

    8w - 80 - 59 zg 8w-80 connector pin-outs j978w-3 zg008059 circuit function back-up lamp switch output park/neutral position switch sense fused ignition switch output (run) cav 1 2 3 l10 18br/lg t41 20bk/wt f83 18yl/dg black park/neutral position switch 1 3 circuit function passenger airbag line 2 pa...

  • Page 1034

    8w - 80 - 60 zg 8w-80 connector pin-outs 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 ...

  • Page 1035

    8w - 80 - 61 zg 8w-80 connector pin-outs j978w-3 zg008061 circuit function front riser down switch sense front riser up switch sense cav 1 2 p20 16rd/lg p18 16yl/lg red passenger power seat front riser motor 1 2 circuit function horizontal forward switch sense horizontal rearward switch sense cav 1 ...

  • Page 1036

    8w - 80 - 62 zg 8w-80 connector pin-outs j978w-3 zg008062 passenger seat heater control module circuit - - - function - - - fused ignition switch output fused b(+) heated seat driver ground passenger heated seat switch output cav 1 2 3 4 5 6 7 8 f87 18wt/bk f35 16rd p87 16bk/or z1 18bk p8 18lb/wt 1 ...

  • Page 1037

    8w - 80 - 63 zg 8w-80 connector pin-outs 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 fron...

  • Page 1038

    8w - 80 - 64 zg 8w-80 connector pin-outs j978w-3 zg008064 circuit function fused b(+) ground cav 1 2 f38 18or z1 18bk power outlet black 2 1 fused ignition switch output (start/run) sensor ground park neutral position switch sense ignition coil no. 1 driver crankshaft position sensor signal idle air...

  • Page 1039

    8w - 80 - 65 zg 8w-80 connector pin-outs j978w-3 zg008065 transmission temperature sensor signal injector no. 7 driver injector no. 1 driver injector no. 3 driver injector no. 5 driver variable force solenoid control generator field driver torque converter clutch solenoid control injector no. 6 driv...

  • Page 1040

    8w - 80 - 66 zg 8w-80 connector pin-outs j978w-3 zg008066 a/c compressor clutch relay control automatic shut down relay control speed control vacuum solenoid control speed control vent solenoid control overdrive off lamp driver vapor canister solenoid driver speed control on/off switch sense automat...

  • Page 1041

    8w - 80 - 67 zg 8w-80 connector pin-outs j978w-3 zg008067 low fuel warning fused b(+) sensor ground 5 volt supply coolant level sensor fused ignition switch output ground ground generator field driver engine coolant temperature sensor signal throttle position sensor signal water-in-fuel sense distri...

  • Page 1042

    8w - 80 - 68 zg 8w-80 connector pin-outs j978w-3 zg008068 circuit - function - left front (-) right front (-) park lamp relay output panel lamp driver fused ignition switch output (acc/run) fused b(+) cav 1 2 3 4 5 6 7 x55 20br/rd x56 20db l90 20db/rd e2 20or x12 18rd/gy f60 20rd/wt radio - c1 gray ...

  • Page 1043

    8w - 80 - 69 zg 8w-80 connector pin-outs 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) rear washer motor control liftgate ajar ...

  • Page 1044

    8w - 80 - 70 zg 8w-80 connector pin-outs j978w-3 zg008070 circuit function right impact sensor line 1 right impact sensor line 2 cav 1 2 r46 18br/lb r48 18tn right airbag sensor black 2 1 circuit function back-up lamp switch output ground cav a g l10 18br/lg z1 18bk black right back-up lamp a g circ...

  • Page 1045

    8w - 80 - 71 zg 8w-80 connector pin-outs 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...

  • Page 1046

    8w - 80 - 72 8w-80 connector pin-outs j978w-3 zg008072 circuit function park lamp relay output turn signal switch output cav a b l90 18db/rd l64 18tn/db gray right front side marker lamp b a circuit function turn signal switch output ground cav a g l64 18tn/db z1 18bk black right front turn signal l...

  • Page 1047

    8w - 80 - 73 zg 8w-80 connector pin-outs j978w-3 zg008073 circuit function park lamp relay output ground cav 1 2 l90 20db/rd z1 20bk natural right license lamp 1 2 circuit function door unlock driver door lock driver cav 1 2 p34 18pk/bk p2 18bk/wt right rear door lock motor black 1 2 circuit functio...

  • Page 1048

    8w - 80 - 74 zg 8w-80 connector pin-outs j978w-3 zg008074 circuit function ground park lamp switch output cav 1 2 z1 18bk l22 18lb natural right rear side marker lamp 1 2 circuit function turn signal switch output ground cav a g l61 18lg z1 18bk black right rear turn signal lamp a g function circuit...

  • Page 1049

    8w - 80 - 75 zg 8w-80 connector pin-outs j978w-3 zg008075 circuit function fused b(+) ground cav a b m1 20pk z1 20bk a right visor/ vanity mirror black b circuit function seat belt switch sense ground cav 1 2 g10 20lg/rd z1 20bk seat belt switch circuit function shift interlock solenoid sense fused ...

  • Page 1050

    8w - 80 - 76 zg 8w-80 connector pin-outs j978w-3 zg008076 speed proportional steering module green circuit - - - function - - - speed proportional steering solenoid control low speed proportional steering solenoid control high steering wheel speed sensor ground 5 volt supply vehicle speed sensor sig...

  • Page 1051

    8w - 80 - 77 zg 8w-80 connector pin-outs j978w-3 zg008077 steering wheel speed sensor circuit function 5 volt supply steering wheel speed sensor ground steering wheel speed sensor signal a steering wheel speed sensor signal b cav a b c d s1 20bk/yl s2 20bk/lg s3 20pk/wt s4 20vt a d natural circuit -...

  • Page 1052

    8w - 80 - 78 zg 8w-80 connector pin-outs j978w-3 zg008078 circuit function 5 volt supply throttle position sensor signal sensor ground cav *1 *2 *3 k25 20wt/bk k22 18or/db k4 20bk/lb black throttle position sensor 3 2 1 circuit function fused b(+) fused b(+) cav a b f70 16pk/bk f70 16pk/bk black a b...

  • Page 1053

    8w - 80 - 79 zg 8w-80 connector pin-outs j978w-3 zg008079 circuit function stop lamp switch output ground fused b(+) factory trailer tow relay outputs factory trailer tow relay outputs cav 1 2 3 4 5 l50 18wt/tn z1 18bk f70 16pk/bk 94 18dg 95 18pk trailer tow stop lamp relay black 3 5 2 4 1 circuit f...

  • Page 1054

    8w - 80 - 80 zg 8w-80 connector pin-outs j978w-3 zg008080 circuit function speed control vacuum solenoid control speed control vent solenoid control speed control stop lamp switch output ground cav 1 2 3 4 v36 18tn/rd v35 18lg/rd v30 20db/lg z4 20bk vehicle speed control servo black 1 4 circuit func...

  • Page 1055

    8w - 80 - 81 zg 8w-80 connector pin-outs j978w-3 zg008081 circuit function washer switch output ground cav a b v11 18tn/bk z2 18bk circuit - function - fused ignition switch output (acc/run) wiper park switch sense ground wiper switch low speed output wiper switch high speed output cav 1 2 3 4 5 6 f...

  • Page 1057

    8w-90 connector locations description and operation introduction this section provides illustrations identifying com- ponent and connector locations in the vehicle. A con- nector index is provided. Use the wiring diagrams in each section for connector number identification. Refer to the index for th...

  • Page 1058

    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 instr...

  • Page 1059

    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...

  • Page 1060

    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 b...

  • Page 1061

    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. 2 gy at injector 5, 8 injector no. 3 gy at injector 5, 9 injector no. 4 gy at injector 5, 8 injector no. 5 gy at injector 5, 9 injector no. 6 gy a...

  • Page 1062

    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...

  • Page 1063

    Connector name/number color location fig. Passenger seat heater control module gy under passenger’s 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 ou...

  • Page 1064

    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 driver’s seat belt clasp 19 shift interlock bk steering column, on shift cable n/s solar sensor rd above glove box 14 speed proportio...

  • Page 1065

    Fig. 1 front end lighting zg 8w - 90 connector locations 8w - 90 - 9 description and operation (continued).

  • Page 1066

    Fig. 2 engine compartment—left side 8w - 90 - 10 8w - 90 connector locations zg description and operation (continued).

  • Page 1067

    Fig. 3 engine compartment—right side zg 8w - 90 connector locations 8w - 90 - 11 description and operation (continued).

  • Page 1068

    Fig. 4 engine compartment connectors 8w - 90 - 12 8w - 90 connector locations zg description and operation (continued).

  • Page 1069

    Fig. 5 engine connectors—4.0l engine zg 8w - 90 connector locations 8w - 90 - 13 description and operation (continued).

  • Page 1070

    Fig. 6 charging system connectors—4.0l engine 8w - 90 - 14 8w - 90 connector locations zg description and operation (continued).

  • Page 1071

    Fig. 7 t ransmission connectors—4.0l engine zg 8w - 90 connector locations 8w - 90 - 15 description and operation (continued).

  • Page 1072

    Fig. 8 engine connectors—5.2l engine 8w - 90 - 16 8w - 90 connector locations zg description and operation (continued).

  • Page 1073

    Fig. 9 engine connectors—5.2l engine zg 8w - 90 connector locations 8w - 90 - 17 description and operation (continued).

  • Page 1074

    Fig. 10 t ransmission connectors—5.2l 8w - 90 - 18 8w - 90 connector locations zg description and operation (continued).

  • Page 1075

    Fig. 1 1 engine connectors—diesel engine zg 8w - 90 connector locations 8w - 90 - 19 description and operation (continued).

  • Page 1076

    Fig. 12 battery and starter motor connectors—diesel engine 8w - 90 - 20 8w - 90 connector locations zg description and operation (continued).

  • Page 1077

    Fig. 13 t ransmission connectors—diesel engine zg 8w - 90 connector locations 8w - 90 - 21 description and operation (continued).

  • Page 1078

    Fig. 14 instrument panel connectors 8w - 90 - 22 8w - 90 connector locations zg description and operation (continued).

  • Page 1079

    Fig. 15 junction block and hv ac unit connectors zg 8w - 90 connector locations 8w - 90 - 23 description and operation (continued).

  • Page 1080

    Fig. 16 instrument panel connectors—left side 8w - 90 - 24 8w - 90 connector locations zg description and operation (continued).

  • Page 1081

    Fig. 17 steering column connectors zg 8w - 90 connector locations 8w - 90 - 25 description and operation (continued).

  • Page 1082

    Fig. 18 roof connectors 8w - 90 - 26 8w - 90 connector locations zg description and operation (continued).

  • Page 1083

    Fig. 19 body connectors—right side zg 8w - 90 connector locations 8w - 90 - 27 description and operation (continued).

  • Page 1084

    Fig. 20 body connectors—left side 8w - 90 - 28 8w - 90 connector locations zg description and operation (continued).

  • Page 1085

    Fig. 21 front door connectors zg 8w - 90 connector locations 8w - 90 - 29 description and operation (continued).

  • Page 1086

    Fig. 22 rear door connectors 8w - 90 - 30 8w - 90 connector locations zg description and operation (continued).

  • Page 1087

    Fig. 23 factory t railer t o w zg 8w - 90 connector locations 8w - 90 - 31 description and operation (continued).

  • Page 1088

    Fig. 24 liftgate connectors 8w - 90 - 32 8w - 90 connector locations zg description and operation (continued).

  • Page 1089

    Fig. 25 underhood lamp fig. 26 license plate lamps zg 8w - 90 connector locations 8w - 90 - 33 description and operation (continued).

  • Page 1091

    8w-95 splice locations description and operation introduction this section provides illustrations identifying the general location of the splices in this vehicle. A splice index is provided. Use the wiring diagrams in each section for splice number identification. Refer to the index for proper splic...

  • Page 1092

    Splice number location fig. S200 near headlamp switch t/o 5 s201 near headlamp switch t/o 5 s202 near stop lamp switch t/o 5 s203 near stop lamp switch t/o 5 s204 near branch to instrument cluster 5 s205 near branch to instrument cluster 5 s206 near branch to rear window defogger switch 5 s207 near ...

  • Page 1093

    Splice number location fig. S404 in right power seat harness, near seat motor t/os n/s s405 in right power seat harness, near seat motor t/os n/s s406 in right power seat harness, in branch to seat switch n/s s407 in left power seat harness, near lumbar motor t/o n/s s408 near left front turn signal...

  • Page 1094

    Fig. 1 engine compartment splices 8w - 95 - 4 8w - 95 splice locations zg description and operation (continued).

  • Page 1095

    Fig. 2 engine w iring splices—4.0l engine zg 8w - 95 splice locations 8w - 95 - 5 description and operation (continued).

  • Page 1096

    Fig. 3 engine w iring splices—5.2l engine 8w - 95 - 6 8w - 95 splice locations zg description and operation (continued).

  • Page 1097

    Fig. 4 engine and t ransmission w iring splices—diesel engine zg 8w - 95 splice locations 8w - 95 - 7 description and operation (continued).

  • Page 1098

    Fig. 5 instrument panel splices 8w - 95 - 8 8w - 95 splice locations zg description and operation (continued).

  • Page 1099

    Fig. 6 body splices fig. 7 hvac harness splices zg 8w - 95 splice locations 8w - 95 - 9 description and operation (continued).

  • Page 1100

    Fig. 8 left body side w iring splices 8w - 95 - 10 8w - 95 splice locations zg description and operation (continued).

  • Page 1101

    Fig. 9 right side body w iring splices zg 8w - 95 splice locations 8w - 95 - 11 description and operation (continued).

  • Page 1102

    Fig. 10 roof wiring splices fig. 11 front door harness splices 8w - 95 - 12 8w - 95 splice locations zg description and operation (continued).

  • Page 1103

    Fig. 12 liftgate splices zg 8w - 95 splice locations 8w - 95 - 13 description and operation (continued).

  • Page 1105: Wiring Diagrams

    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 chargin...

  • Page 1107

    8w-01 general information index page page description and operation circuit identification . . . . . . . . . . . . . . . . . 3 connector/ground locations . . . . . . . . . 1 connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 3 electrostatic discharge (esd) sensitive devices . . . . . . ....

  • Page 1108

    That may appear on the vehicle. For example, an up-to and after condition. Cautions are used to indicate information that could prevent making an error that may damage the vehicle. Warnings provide information to prevent per- sonal injury and vehicle damage. Below is a list of general warnings that ...

  • Page 1109

    Circuit identification all circuits in the diagrams use an alpha/numeric code to identify the wire and its function (fig. 3). To identify which circuit code applies to a system, refer to the circuit identification code chart. This chart shows the main circuits only and does not show the secondary co...

  • Page 1110

    Fig. 5 symbol identification 8w - 01 - 4 8w - 01 general information zg description and operation (continued).

  • Page 1111

    Electrostatic discharge (esd) sensitive devices all esd sensitive components are solid state and a symbol (fig. 6) is used to indicate this. When han- dling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and ...

  • Page 1112

    Troubleshooting tests before beginning any tests on a vehicles electrical system use the wiring diagrams and study the cir- cuit. Also refer to the troubleshooting wiring prob- lems section in this section. Testing for voltage (1) connect the ground lead of a voltmeter to a known good ground (fig. 8...

  • Page 1113

    (3) analyze the symptoms. Use the wiring dia- grams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. (4) isolate the problem area. (5) repair the problem. (6) verify proper operation. For this step check for proper operation of...

  • Page 1114

    (4) using special tool 6742 release the locking fin- gers on the terminal (fig. 13). (5) pull on the wire to remove it from the connec- tor. (6) repair or replace the connector or terminal, as necessary. Terminal/connector repair—thomas and betts connectors (1) disconnect battery. (2) disconnect the...

  • Page 1115

    (4) position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (fig. 18) (fig. 19). (5) reset the terminal locking tang, if it has one. (6) insert the removed wire in the same cavity on the...

  • Page 1116

    (3) remove connector locking wedge, if required (fig. 21). (4) position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (fig. 22) (fig. 23). (5) cut the wire 6 inches from the back of the...

  • Page 1117

    (4) remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. (5) install the new diode in the harness, making sure current flow is correct. If necessary refer to the appropriate wiring diagram for current flow. (6) solder the connection together ...

  • Page 1119

    8w-02 component index index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1120

    Component page fuel heater relay . . . . . . . . . . . . . . . . . . . . . 8w-30 fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . 8w-30 fuel pump module . . . . . . . . . . . . . . . . . . . . . 8w-30 fuel pump relay . . . . . . . . . . . . . . . . . . . . . . 8w-30 fuel sender unit ...

  • Page 1121

    Component page sliding roof position switch . . . . . . . . . . . . . 8w-64 solar sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 8w-42 speed proportional steering control module . 8w-65 speed proportional steering module . . . . . . . 8w-65 speed proportional steering solenoid . . . . . ...

  • Page 1122

    8w-02 component index general information introduction this section provides an alphabetical listing of all the components covered in group 8w. For information on system operation, refer to the appropriate section of the wiring diagrams. 8w - 02 - 4 8w - 02 component index zg.

  • Page 1123

    8w-10 power distribution index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1124

    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 ...

  • Page 1125

    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/...

  • Page 1126

    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...

  • Page 1127

    5 fuse 50a 4 11 a10 10 rd/db 25 controller anti-lock brake batt a0 5 12 6 fuse 20a relay horn a2 a3 a1 fused b(+) x2 16 dg/yl s106 x2 16 dg/yl x2 16 dg/yl 1 1 no. 1 horn no. 2 horn center distribution power (8w-39-6) (8w-41-2) (8w-10-3) (8w-39-6) (8w-41-2) (8w-39-6) (8w-41-2) (8w-35-2) (8w-10-3) zg-...

  • Page 1128

    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 mot...

  • Page 1129

    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 c23...

  • Page 1130

    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) ...

  • Page 1131

    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...

  • Page 1132

    17 24 11 fuse 50a a250 10 rd c2 4 junction block 30a 2 breaker circuit 15a fuse 9 batt a0 20a fuse 7 20a fuse 8 14 fuse 20a 27 20 a20 14 rd/lg 9 controller anti-lock brake fused b(+) center distribution power (8w-10-3) (8w-35-2) (8w-12-8) (8w-12-8) (8w-12-7) (8w-12-7) (8w-12-2) (8w-10-3) 8w - 10 - 1...

  • Page 1133

    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 distribu...

  • Page 1134

    28 21 15 fuse 40a batt a0 a7 12 yl/rd c2 2 junction block 15a fuse 13 16 fuse 10a 15a fuse 19 20 fuse 15a 15a fuse 21 20a 3 breaker circuit center distribution power (8w-10-3) (8w-12-18) (8w-12-16) (8w-12-16) (8w-12-16) (8w-12-12) (8w-12-11) (8w-12-2) (8w-10-3) 8w - 10 - 12 8w-10 power distribution ...

  • Page 1135

    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 ...

  • Page 1137

    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 solenoi...

  • Page 1138

    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) ...

  • Page 1139

    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 ...

  • Page 1140

    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 heat...

  • Page 1141

    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 ...

  • Page 1142

    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 ...

  • Page 1143

    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 f25...

  • Page 1144

    Automatic shut down relay b17 b16 f5 16rd/yl * fused ignition switch output (st/run) f5 16rd/yl * b16 cav circuit function b16 f5 18rd/yl fused b(+) fused b(+) fused b(+) wiper park switch sense v6 16db function circuit cav c1 f86 16lg/rd * f86 18lg/rd ** c2 c3 f86 16lg/rd relay wiper intermittent a...

  • Page 1145

    - - c9 c8 t141 14yl/rd fused ignition switch output (st) t40 12lg/bk c7 cav circuit function c6 a1 12rd/wt fused b(+) engine starter motor relay output fuel pump relay output fused b(+) a61 16dg/bk function circuit cav c16 a64 16dg/wt f99 200r c17 c18 - relay pump fuel z4 20bk c10 park neutral posit...

  • Page 1146

    8w-10 power distribution description and operation this section covers the power distribution center and all circuits involved with it. For additional infor- mation on system operation, refer to the appropriate wiring diagrams. 8w - 10 - 24 8w - 10 power distribution zg.

  • Page 1147

    8w-12 junction block index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1148

    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...

  • Page 1149

    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 ju...

  • Page 1150

    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 ...

  • Page 1151

    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...

  • Page 1152

    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 ...

  • Page 1153

    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 ...

  • Page 1154

    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...

  • Page 1155

    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...

  • Page 1156

    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 pas...

  • Page 1157

    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 ...

  • Page 1158

    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) ju...

  • Page 1159

    M1 20 pk a lamp vanity visor/ right left visor/ vanity lamp a m1 20 pk m1 20 pk dome/ reading lamp c 6 overhead console m1 20 pk s321 m1 20 pk d (8w-12-12) junction block from (8w-49-3) (8w-44-3) (8w-44-5) (8w-44-5) zg-rhd 8w-12 junction block 8w - 12 - 13 zgr01212 j978w-3.

  • Page 1160

    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) (...

  • Page 1161

    C13 4 l90 18 db/rd (optional) module outage lamp 3 4 5 l90 18db/rd l90 18db/rd from junction block output 9 c3 l90 18 db/rd 2 c102 2 c150 l90 18 db/rd l90 18 db/rd l90 18 db/rd l90 18 db/rd s103 l90 18 db/rd a lamp park front s410 front park lamp a db/rd 18 l90 s415 11 vehicle information center c8 ...

  • Page 1162

    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...

  • Page 1163

    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 trail...

  • Page 1164

    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 sea...

  • Page 1165

    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 gr...

  • Page 1166

    Batt f61 10a fuse 15 86 30 87 a16 a15 85 15 switch headlamp 7 c7 c7 10 3 c7 l95 18 dg/yl a relay lamp fog rear c7 6 1 lamp outage module l96 20 lg/rd l36 18 lg l36 18 lg/or 7 c307 junction block (8w-10-9) (8w-50-7) (8w-51-7) (8w-12-2) 8w - 12 - 20 8w-12 junction block zg-rhd j978w-3 zgr01219.

  • Page 1167

    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 ov...

  • Page 1168

    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 z...

  • Page 1169

    A5 (in pdc) c7 12 c3 1 7 c10 x4 20 gy/or x4 20 gy/or 5 switch horn control/ speed vehicle c2 13 module control body x4 20 gy/or 10a fuse 22 run a22 c13 1 airbag control module 20 fused ign. (run) f20 18 wt relay horn junction block (8w-43-2) (8w-10-8) (8w-45-3) (8w-41-2) (8w-41-2) (8w-12-2) zg-rhd 8...

  • Page 1170

    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 ...

  • Page 1171

    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 14...

  • Page 1172

    20a feed circuit size circuit breaker 1 * a31 12rd/bk 30a 87 l36 18lg rear fog lamp 86 l95 18dg/yl relay output l96 20lg/rd 85 cavity circuit function 30 f61 16wt/or fused b(+) internal 30 function circuit cav 85 z1 20bk ground fused ignition switch ouput (run) a31 rd/bk 86 87 fused ignition switch ...

  • Page 1173

    C15 bk/wt rear window defogger relay output 87 86 a900 or/yl fused b(+) c14 wt/rd 85 cavity circuit function 30 a900 or/yl fused b(+) rear window defogger relay control fused b(+) ground function circuit - 87a - power antenna driver radio 12 volt output power antenna down control 5 4 3 2 1 cavity x1...

  • Page 1174

    Cavity circuit function 30 m2 yl courtesy lamp relay output courtesy lamp relay control m112 br/lg 85 86 m1 pk fused b(+) 87 z1 bk ground - - 87a courtesy lamp relay (c) (d) relay lamp fog 87a - - fog lamp relay output l39 lb 87 fused b(+) f62 rd 86 85 l95 dg/yl fog lamp relay control fused b(+) f62...

  • Page 1175

    8w-12 junction block description and operation this section covers the junction block and all cir- cuits involved with it. For additional information on system operation, please refer to the appropriate sec- tion of the wiring diagrams. Zg 8w - 12 junction block 8w - 12 - 29.

  • Page 1177

    8w-15 ground distribution index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1178

    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-...

  • Page 1179

    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...

  • Page 1180

    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 1...

  • Page 1181

    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 wash...

  • Page 1182

    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 ...

  • Page 1183

    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...

  • Page 1184

    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...

  • Page 1185

    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...

  • Page 1186

    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 (...

  • Page 1187

    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 r...

  • Page 1188

    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 c32...

  • Page 1189

    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 ...

  • Page 1190

    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) s...

  • Page 1191

    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 dri...

  • Page 1192

    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 courtes...

  • Page 1193

    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 ...

  • Page 1194

    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...

  • Page 1195

    8w-15 ground distribution description and operation this section identifies the grounds, splices that connect to those grounds, and the components that connect those grounds. For additional information on system operation, refer to the appropriate section of the wiring diagrams. For an illustration ...

  • Page 1197

    8w-20 charging system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1198

    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-7...

  • Page 1199

    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 g10...

  • Page 1200

    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 con...

  • Page 1201

    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 ...

  • Page 1202

    8w-20 charging system description and operation charging system the charging system is an integral part of the bat- tery and starting systems. Because all these systems work in conjunction, diagnose and test them together. Circuit a11 connects to the generator output termi- nal and the power distrib...

  • Page 1203

    8w-21 starting system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1204

    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 ...

  • Page 1205

    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 t...

  • Page 1206

    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 ne...

  • Page 1207

    8w-21 starting system description and operation starting system circuit a0 from the battery is double crimped at the positive battery post. One branch of circuit a0 (battery positive cable) connects to the engine starter motor. The other a0 branch supplies voltage to the power distribution center (p...

  • Page 1209

    8w-30 fuel/ignition systems index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1210

    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...

  • Page 1211

    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 sole...

  • Page 1212

    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/ pur...

  • Page 1213

    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 d...

  • Page 1214

    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 pow...

  • Page 1215

    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...

  • Page 1216

    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 sen...

  • Page 1217

    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 sen...

  • Page 1218

    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...

  • Page 1219

    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...

  • Page 1220

    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 in...

  • Page 1221

    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 sen...

  • Page 1222

    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 sig...

  • Page 1223

    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 ...

  • Page 1224

    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 fu...

  • Page 1225

    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 a...

  • Page 1226

    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/b...

  • Page 1227

    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...

  • Page 1228

    C1 a11 2 3 1 4 idle air control motor a19 c1 c1 a20 a10 c1 iac motor no. 3 driver driver no. 2 motor iac iac motor no. 1 driver driver no. 4 motor iac module control powertrain k40 16 br/wt k60 16 yl/bk k39 16 gy/rd k59 16 vt/bk no. 3 motor iac motor no. 2 iac no. 1 motor iac no. 4 motor iac 8w - 30...

  • Page 1229

    C1 a11 3 2 4 1 idle air control motor a19 c1 c1 a20 a10 c1 iac motor no. 3 driver driver no. 2 motor iac iac motor no. 1 driver driver no. 4 motor iac module control powertrain k40 16 br/wt k60 16 yl/bk k39 16 gy/rd k59 16 vt/bk no. 3 motor iac motor no. 2 iac iac no. 1 motor no. 4 motor iac zg-rhd ...

  • Page 1230

    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 (...

  • Page 1231

    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 ...

  • Page 1232

    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 ve...

  • Page 1233

    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 (-) ...

  • Page 1234

    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 m...

  • Page 1235

    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...

  • Page 1236

    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/d...

  • Page 1237

    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/...

  • Page 1238

    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/p...

  • Page 1239

    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...

  • Page 1240

    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 ...

  • Page 1241

    8w-30 fuel/ignition systems index page page description and operation accelerator pedal position sensor (diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 automatic shut down (asd) relay . . . . . 34 automatic shut down relay (diesel) . . . 34 battery feed (diesel) . . . . . . . . ....

  • Page 1242

    Pcm ground (diesel) ground for the powertrain control module (pcm) is supplied on the z12 circuit. This circuit connects to four cavities in the pcm and terminates at the pcm ground location. Data link connector circuit a250 from fuse 11 in the power distribu- tion center (pdc) powers circuit f75 th...

  • Page 1243

    Fuel level sensor the fuel level sensor is a variable resistor. Circuit g40 provides the fuel level input to the powertrain control module (pcm). The pcm broadcasts fuel level data on the ccd bus. The micro-processor in the instrument cluster receives the message on the ccd bus, calculates fuel gaug...

  • Page 1244

    • manifold absolute pressure sensor • oil pressure sensor • powertrain control module • throttle position sensor • transmission solenoid assembly • upstream heated oxygen sensor • vehicle speed control switch • vehicle speed sensor crankshaft position sensor (diesel) the powertrain control module (p...

  • Page 1245

    Circuit k22 delivers the tps signal to the pcm. Circuit k22 connects to cavity a23 of the pcm. The pcm provides a ground for the throttle posi- tion sensor signal (circuit k22) through circuit k4. Circuit k4 connects to cavity a4 of the pcm. Helpful information refer to group 14 for throttle positio...

  • Page 1246

    • transmission solenoid assembly • upstream heated oxygen sensor • vehicle speed control switch • vehicle speed sensor oil pressure sensor the oil pressure sensor is a variable resistor. A change in engine oil pressure changes the resistance in the sending unit which alters the signal sensed by the ...

  • Page 1247

    Fuel quantity actuator power for the fuel quantity actuator is supplied on circuit a142. This circuit is hot when the contacts in the diesel powertrain control module (pcm) relay are closed. Ground for the actuator is controlled by the pcm on circuit k140. Fuel heater (diesel) when the ignition swit...

  • Page 1249

    8w-31 transmission control system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1250

    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 converte...

  • Page 1251

    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 pow...

  • Page 1252

    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...

  • Page 1253

    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 lam...

  • Page 1254

    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/...

  • Page 1255

    8w-31 transmission control system index page page description and operation governor pressure sensor . . . . . . . . . . . 7 output shaft speed sensor . . . . . . . . . . . 7 overdrive switch . . . . . . . . . . . . . . . . . . . . . 7 shift interlock . . . . . . . . . . . . . . . . . . . . . . . 7 ...

  • Page 1256

    B29 of the pcm. Circuit k6 from cavity b31 of the pcm supplies 5 volts to the sensor. The pcm pro- vides ground for the govenor pressure sensor on cir- cuit k4. Circuit k4 connects to cavity a4 of the pcm. The governor pressure sensor is part of the trans- mission solenoid assembly. Transmission tem...

  • Page 1257

    8w-33 vehicle speed control index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1258

    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/l...

  • Page 1259

    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 v...

  • Page 1260

    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 ...

  • Page 1261

    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 ...

  • Page 1262

    8w-33 vehicle speed control description and operation vehicle speed control the powertrain control module (pcm) operates the vehicle speed control system. The vehicle speed control switches are located in the steering wheel. Circuit v32 from cavity c11 of the pcm connects to circuit v30 through the ...

  • Page 1263

    8w-35 all-wheel anti-lock brakes index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1264

    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 (+) jun...

  • Page 1265

    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 switc...

  • Page 1266

    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 whe...

  • Page 1267

    8w-35 all-wheel anti-lock brakes index page page description and operation abs warning lamp . . . . . . . . . . . . . . . . . . . . . 5 data link connector . . . . . . . . . . . . . . . . . . 5 g-switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 introduction . . . . . . . . . . . . ...

  • Page 1269

    8w-39 vehicle theft security system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1275

    8w-39 vehicle theft security system index page page description and operation introduction . . . . . . . . . . . . . . . . . . . . . . . . . 7 vehicle theft security system operation . . . . . . . . . . . . . . . . . . . . . . . . . . 7 description and operation introduction the body control module ...

  • Page 1277

    8w-40 instrument cluster index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1278

    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 inst...

  • Page 1279

    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...

  • Page 1280

    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...

  • Page 1281

    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 c...

  • Page 1282

    3 g9 18 gy/bk f5 c234 gy/bk 16 g9 switch warning brake g9 16 gy/bk gas others 2 c304 g9 20 gy/bk s303 g9 20 gy/bk 2 c3 brake switch sense body control module 3 0 2 1 ignition switch 1 start 2 run 0 off 3 acc 2 1 gy/bk 20 g9 (8w-10-7) (8w-45-9) (8w-45-9) (8w-50-4) 8w - 40 - 6 8w-40 instrument cluster...

  • Page 1283

    8w-40 instrument cluster index page page description and operation abs warning lamp . . . . . . . . . . . . . . . . . . . . . 7 engine coolant temperature gauge . . . 7 fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 high beam indicator lamp . . . . . . . . . . . . . . 8 illuminat...

  • Page 1284

    Powertrain control module (pcm) transmits the data over the ccd bus. High beam indicator lamp the micro-processor in the instrument cluster switches the high beam indicator lamp on and off through a transistor in lamps ground circuit. The body control module (bcm) signals the instrument cluster micr...

  • Page 1285

    8w-41 horn/cigar lighter index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1286

    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 ...

  • Page 1287

    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...

  • Page 1288

    8w-41 horn/cigar lighter description and operation horn the horn system is powered by circuit f31 from fuse 6 in the power distribution center (pdc). Cir- cuit f31 supplies voltage to the coil and contact sides of the horn relay in the pdc. When the operator presses the horn switch, a ground path is...

  • Page 1289

    8w-42 air conditioning/heater index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1290

    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...

  • Page 1291

    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 aut...

  • Page 1292

    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 con...

  • Page 1293

    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 ...

  • Page 1294

    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 c...

  • Page 1295

    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...

  • Page 1296

    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 b...

  • Page 1297

    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...

  • Page 1298

    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 comp...

  • Page 1299

    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 1...

  • Page 1300

    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 ...

  • Page 1301

    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 power...

  • Page 1302

    8w-42 air conditioning/heater index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 14 description and operation a/c operation—automatic temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 a/c operation—manual a/c . . . . . . . . . ...

  • Page 1303

    Module (bcm) receives the a/c select signal on cir- cuit c90. After receiving the input, the bcm signals the powertrain control module (pcm) on the ccd bus. The a/c low pressure and high pressure switches are wired in series and connect to ground on circuit z1. Circuit c3 from the pcm connects to th...

  • Page 1304

    Pressure switch connects circuit c21 to ground cir- cuit z1. If the a/c low pressure and high pressure switches are closed, the pcm senses the a/c request signal on circuit c3. After sensing the a/c request signal, the pcm sup- plies ground for the coil side of a/c compressor clutch relay on circuit...

  • Page 1305

    8w-43 airbag system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1306

    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 pa...

  • Page 1307

    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/...

  • Page 1308

    8w-43 airbag system index page page description and operation airbag impact sensor . . . . . . . . . . . . . . . . . 4 airbag squib (airbag igniter) . . . . . . . . . . 4 airbag warning lamp . . . . . . . . . . . . . . . . . . 4 introduction . . . . . . . . . . . . . . . . . . . . . . . . . 4 descri...

  • Page 1309

    8w-44 interior lighting index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1310

    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 ...

  • Page 1311

    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-...

  • Page 1312

    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-12-1...

  • Page 1313

    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...

  • Page 1314

    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)...

  • Page 1315

    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/w...

  • Page 1316

    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 ampli...

  • Page 1317

    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...

  • Page 1318

    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...

  • Page 1319

    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 1...

  • Page 1320

    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 autom...

  • Page 1321

    3 0 1 2 3 auto 2 park 1 head 0 off switch headlamp panel lamp dimmer switch signal panel lamp driver body control module 2 z1 16 bk z1 14 bk z1 14 bk e2 20 or 707 20 bk/wt g304 s202 2 c301 e2 20 or 20 c2 16 c2 1 8 s209 lamps illumination batt a6 15a fuse 17 11 c9 366 16 pk/or 15 junction block zg-rh...

  • Page 1322

    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 aj...

  • Page 1323

    8w-44 interior lighting index page page description and operation courtesy lamps, cargo lamp, ignition switch key-in halo lamp . . . . . . . . . . . . . 15 day/night mirror . . . . . . . . . . . . . . . . . . . . . 16 glove box lamp . . . . . . . . . . . . . . . . . . . . . . 16 illumination lamps ....

  • Page 1324

    Liftgate courtesy lamp disable switch when closed, the liftgate disable switch provides signal to the bcm on circuit m4 indicating a request to disable the courtesy lamps. To operate, all the doors must be closed with only the liftgate open. Pushing on the liftgate lens activates the switch. Pushing...

  • Page 1325

    8w-45 body control module index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1326

    3 fuse 10a run-acc a31 block junction a16 a15 15a fuse 18 v23 20 br/pk c1 16 c1 18 f99 18 or f99 20 or f99 20 or s101 h8 c236 body control module 15 c2 fused ign. (run-acc) (run-st) ign. Fused 8 c3 c2 24 ground ground ground g304 s302 z2 20 bk/or z2 18 bk/or z2 18 bk/or z2 18 bk/or z2 18 bk/or z1 16...

  • Page 1327

    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 ...

  • Page 1328

    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...

  • Page 1329

    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 contro...

  • Page 1330

    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 contr...

  • Page 1331

    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 1...

  • Page 1332

    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...

  • Page 1333

    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 au...

  • Page 1334

    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 h...

  • Page 1335

    S329 g78 20 tn/bk 3 c325 1 2 switch ajar liftgate liftglass 1 switch ajar 2 a (8w-45-10) c321 from g78 tn/bk 20 tn/bk g78 20 20 g78 tn/bk rear wiper module 6 z1 bk 20 12 bk z1 20 bk z1 bk 12 z1 s328 12 bk z1 g300 s328 2 (8w-15-11) (8w-15-10) (8w-53-4) zg-rhd 8w-45 body control module 8w - 45 - 11 zg...

  • Page 1336

    8w-45 body control module index page page description and operation a/c select switch . . . . . . . . . . . . . . . . . . . . 12 ajar chime . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ambient temperature sensor . . . . . . . . . 12 auto headlamps . . . . . . . . . . . . . . . . . . . . ...

  • Page 1337

    Liftgate courtesy lamp disable switch when the courtesy lamp disable switch closes, it provides battery voltage to the body control module (bcm) on circuit m4. Auto headlamps when the operator puts the headlamp switch in the auto position, the auto headlamp switch closes and connects circuit l24 fro...

  • Page 1339

    8w-46 message center index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1340

    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 b...

  • Page 1341

    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/o...

  • Page 1342

    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 b...

  • Page 1343

    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/o...

  • Page 1344

    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 z...

  • Page 1345

    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 ...

  • Page 1346

    8w-46 message center index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . . 8 description and operation graphic display module . . . . . . . . . . . . . . . 8 vehicle information center . . . . . . . . . . . 8 general information introduction each four-whe...

  • Page 1347

    When the transfer case switch is in part time 4wd position, it connects circuit t107 from the vic to ground on circuit z12. In addition to illuminating the 4wd display, the vic also illuminates the part time display. When the transfer case switch is in full time 4wd position, it connects circuit t10...

  • Page 1349

    8w-47 audio system index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1350

    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 ...

  • Page 1351

    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 ...

  • Page 1352

    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 ...

  • Page 1353

    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 le...

  • Page 1354

    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 ...

  • Page 1355

    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 ri...

  • Page 1356

    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/...

  • Page 1357

    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 ...

  • Page 1358

    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...

  • Page 1359

    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 rea...

  • Page 1360

    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 ...

  • Page 1361

    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.

  • Page 1362

    8w-47 audio system index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . . 14 description and operation amplifier and speakers—premium . . . . . 14 limited plus system . . . . . . . . . . . . . . . . . . 15 power antenna—export only . . . . . . . . . 15 radio...

  • Page 1363

    To the left instrument panel speaker and left front door speaker. Circuit x85 is the return from speakers to the amplifier and circuit x55 is the return from the amplifier to the radio. Circuits x87 and x85 from the amplifier connect to circuits x55 and x53 at the jumper harness for the left front d...

  • Page 1365

    8w-48 rear window defogger index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1366

    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 1...

  • Page 1367

    8w-48 rear window defogger description and operation rear window defogger the body control module (bcm) operates the rear window defogger system through a relay located in the junction block. When the operator presses the rear window defogger switch, the switch connects cir- cuit c80 from the bcm to...

  • Page 1369

    8w-49 overhead console index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1370

    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 2...

  • Page 1371

    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...

  • Page 1372

    8w-49 overhead console description and operation overhead console when the ignition switch is in the run position, it connects circuit a1 from fuse 8 in the power distri- bution center (pdc) to circuit a22. Circuit a22 pow- ers circuit f83 through fuse 6 in the junction block. Circuit f83 supplies p...

  • Page 1373

    8w-50 front lighting index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1374

    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 l...

  • Page 1375

    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...

  • Page 1376

    1 brake warning switch 2 c304 s303 g9 20 gy/bk g9 18 gy/bk switch brake park g9 20 gy/bk module control body c3 2 brake switch sense (8w-45-9) (8w-40-6) 8w - 50 - 4 8w-50 front lighting zg-rhd j978w-3 zgr05003.

  • Page 1377

    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 sen...

  • Page 1378

    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 rig...

  • Page 1379

    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 sens...

  • Page 1380

    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 l9...

  • Page 1381

    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/ tu...

  • Page 1382

    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 ...

  • Page 1383

    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 ...

  • Page 1384

    8w-50 front lighting index page page description and operation auto headlamps . . . . . . . . . . . . . . . . . . . . . 12 fog lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 headlamp leveling . . . . . . . . . . . . . . . . . . . 12 headlamps . . . . . . . . . . . . . . . . . . . . ....

  • Page 1385

    Lamp high beam operation on circuit l3, it energizes the fog lamp relay. The bcm energizes the relay by grounding the relay coil on circuit l95. Circuit f62 from fuse 19 in the power distribution center (pdc) powers the relay coil and contacts. When the fog lamp relay energizes, it connects cir- cui...

  • Page 1387

    8w-51 rear lighting index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1388

    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...

  • Page 1389

    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 l...

  • Page 1390

    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 ...

  • Page 1391

    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....

  • Page 1392

    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/...

  • Page 1393

    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 m...

  • Page 1394

    8w-51 rear lighting description and operation tail lamps, rear license plate lamps and side marker lamps circuit a6 from fuse 13 in the power distribution center (pdc) feeds circuit 366 through fuse 17 in the junction block. Circuit 366 connects to the headlamp switch. When the headlamp switch is in...

  • Page 1395

    8w-52 turn signals index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1396

    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...

  • Page 1397

    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 1...

  • Page 1398

    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 hazar...

  • Page 1399

    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...

  • Page 1400

    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 c3...

  • Page 1401

    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...

  • Page 1402

    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 d...

  • Page 1403

    8w-52 turn signals description and operation electronic flasher relay the electronic flasher relay in the junction block supplies battery voltage to the turn signal/hazard switch circuitry in the multi-function switch. When the ignition switch is off, the hazard flashers will operate but the turn si...

  • Page 1405

    8w-53 wipers index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1406

    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 windshie...

  • Page 1407

    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...

  • Page 1408

    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 v...

  • Page 1409

    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 info...

  • Page 1410

    8w-53 wipers description and operation intermittent wiper operation in the accessory or run position, the ignition switch connects circuit a1 from fuse 8 in the pdc to circuit a31. Circuit a31 powers circuit f86 through the circuit breaker in cavity 1 of the junction block. Circuit f86 supplies powe...

  • Page 1411

    8w-54 trailer tow index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1412

    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 t...

  • Page 1413

    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...

  • Page 1414

    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 1...

  • Page 1415

    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 sw...

  • Page 1416

    8w-54 trailer tow general information introduction two trailer tow packages are available; a factory installed package and a package with after-market provisions. This section provides separate wiring dia- grams for each. Description and operation trailer tow—factory installed the factory installed ...

  • Page 1417

    8w-60 power windows index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1418

    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 ...

  • Page 1419

    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 ...

  • Page 1420

    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...

  • Page 1421

    8w-60 power windows index page page description and operation introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5 power windows . . . . . . . . . . . . . . . . . . . . . . 5 description and operation introduction all four power windows can be controlled by the switches on the drivers do...

  • Page 1422

    For window up operation the circuits are reversed. The ddm powers circuit q17 and grounds circuit q27. Right rear window circuits q18 and q28 connect the passenger’s door module (pdm) to the right rear window switch. When the operator has not selected the window lock- out feature, the pdm connects c...

  • Page 1423

    8w-61 power door locks index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1424

    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 ...

  • Page 1425

    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...

  • Page 1426

    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 ...

  • Page 1427

    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...

  • Page 1428

    8w-61 power door locks description and operation introduction the drivers door module (ddm) powers the driv- ers door lock motor. The passengers door module (pdm) powers the passenger, both rear doorlock and the liftgate lock motors. The ddm and pdm each contain a door lock switch. When one of the s...

  • Page 1429

    8w-62 power mirrors index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1430

    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 c...

  • Page 1431

    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 ...

  • Page 1432

    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...

  • Page 1433

    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 ...

  • Page 1434

    8w-62 power mirrors description and operation introduction the drivers door module (ddm) controls both power mirrors. The ddm adjusts the left mirror and signals the passenger door module (pdm) over the ccd bus to adjust the right mirror. A push button switch on the outside of the ddm controls the h...

  • Page 1435

    8w-63 power seat index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1436

    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 junct...

  • Page 1437

    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-...

  • Page 1438

    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-1...

  • Page 1439

    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)...

  • Page 1440

    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 ...

  • Page 1441

    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 mod...

  • Page 1442

    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 ...

  • Page 1443

    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 s3...

  • Page 1444

    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 ...

  • Page 1445

    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 ...

  • Page 1446

    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/b...

  • Page 1447

    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 c...

  • Page 1448

    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 ...

  • Page 1449

    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 switche...

  • Page 1450

    8w-63 power seat index page page description and operation heated seats . . . . . . . . . . . . . . . . . . . . . . . . 17 introduction . . . . . . . . . . . . . . . . . . . . . . . . 16 memory seats . . . . . . . . . . . . . . . . . . . . . . . 17 power seats . . . . . . . . . . . . . . . . . . . ....

  • Page 1451

    A bus bar internal to the switch connects circuit p12 to ground on circuit z1. For rear vertical down function the circuits are reversed. P12 is the feed, and p10 is the ground. When the operator selects the front vertical up function, the switch passes power from circuit f35 to circuit p18. Circuit...

  • Page 1452

    When the ignition switch is in the run position, it connects circuit a1 from fuse 8 in the pdc to circuit a22. Circuit a22 powers circuit f71 through fuse 12 in the junction block. Circuit f71 splices to supply power to the driver and passenger heated seat switches and provides an input to the heate...

  • Page 1453

    8w-64 power sunroof index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1454

    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...

  • Page 1455

    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 - ...

  • Page 1456

    8w-64 power sunroof index page description and operation power sunroof . . . . . . . . . . . . . . . . . . . . . . 4 description and operation power sunroof when the ignition switch is in the accessory or run position it connects circuit a1 from fuse 8 in the power distribution center (pdc) to circu...

  • Page 1457

    8w-65 speed proportional steering index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 1458

    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...

  • Page 1459

    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 pro...

  • Page 1460

    8w-65 speed proportional steering index page page description and operation data link connector . . . . . . . . . . . . . . . . . . 4 introduction . . . . . . . . . . . . . . . . . . . . . . . . . 4 speed proportional steering control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 1461

    8w-70 splice information index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 component page s100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8w-10-16 s101 . . . . . . . . . . . . ...

  • Page 1462

    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 p...

  • Page 1463

    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 sens...

  • Page 1464

    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...

  • Page 1465

    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 1...

  • Page 1466

    4 2 fuel sender unit sensor level coolant s102 k167 20 br/yl k167 20 br/yl k167 20 br/yl 15 c304 c4 4 module control powertrain k167 20 br/yl k167 20 br/yl k167 20 br/yl 12 c132 s141 (8w-30-28) (8w-30-29) (8w-30-28) (8w-30-29) (8w-70-9) 8w - 70 - 6 8w-70 splice information diesel engine zg-rhd j978w...

  • Page 1467

    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 a14...

  • Page 1468

    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 ...

  • Page 1469

    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...

  • Page 1471

    8w-80 connector pin-outs index page schematics and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 component page a/c heater control - c1 . . . . . . . . . . . . . . . 8w-80-5 a/c heater control - c2 . . . . . . . . . ....

  • Page 1472

    Component page dome/reading lamp . . . . . . . . . . . . . . . . . 8w-80-29 downstream heated oxygen sensor . . . . . 8w-80-29 driver door module - c1 . . . . . . . . . . . . . . 8w-80-29 driver door module - c2 . . . . . . . . . . . . . . 8w-80-29 driver door module - c3 . . . . . . . . . . . . . ....

  • Page 1473

    Component page left rear door speaker . . . . . . . . . . . . . . . 8w-80-51 left rear fog lamp . . . . . . . . . . . . . . . . . 8w-80-51 left rear power window motor . . . . . . . . 8w-80-52 left rear power window switch . . . . . . . . 8w-80-52 left rear side marker lamp . . . . . . . . . . 8w-80...

  • Page 1474

    Component page transmission solenoid assembly . . . . . . . . 8w-80-79 underhood lamp . . . . . . . . . . . . . . . . . . . . 8w-80-79 upstream heated oxygen sensor . . . . . . . 8w-80-79 vehicle information center . . . . . . . . . . . . 8w-80-80 vehicle speed control servo . . . . . . . . . . . 8w...

  • Page 1475

    8w - 80 - 5 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08005 c36 20db/rd c34 20vt/wt e2 20or f71 20dg/pk c90 20lg circuit - - function - - blend air door position switch signal ground panel lamp driver fused ignition switch output (run) a/c select input cav 1 2 3 4 5 6 7 a/c-heater control - c2 blac...

  • Page 1476

    8w - 80 - 6 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08006 airbag control module black circuit - - - - - - - - - - - - - function - - - - - - - - - - - - - driver airbag line 2 driver airbag line 1 passenger airbag line 1 passenger airbag line 2 ground fused ignition switch output (run/start) ccd ...

  • Page 1477

    8w - 80 - 7 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08007 circuit - - - - - - - - - - function - - - - - - - - - - mode door motor driver blend air door motor driver mode door motor position sense a/c select input 5 volt supply blower power module output ccd bus(+) ccd bus(-) fused ignition switc...

  • Page 1478

    8w - 80 - 8 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08008 circuit - function - 5 volt supply blend air door feedback signal sensor return blend air door motor driver blend air door motor driver cav 1 2 3 4 5 6 c40 20dg/yl c36 20db/rd d41 20lg/wt c35 20db/wt c34 20vt/wt blend door actuator (with a...

  • Page 1479

    8w - 80 - 9 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08009 circuit - - - - - - - function - - - - - - - windshield wiper switch signal sensor return ambient temperature sensor signal switched courtesy lamp feed auto headlamp switch sense rear window defogger switch sense dimmer switch low beam out...

  • Page 1480

    Zg-rhd 8w - 80 - 10 8w-80 connector pin-outs j978w-3 zgr08010 circuit - - - - - function - - - - - ultralight sensor driver radio control mux wiper park switch sense courtesy lamp relay control a/c select input fused b(+) ultralight sensor signal auto headlamp relay control horn relay control rear w...

  • Page 1481

    8w - 80 - 11 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08011 circuit function red brake warning lamp driver red brake warning lamp driver cav 1 2 g9 16gy/bk g9 16gy/bk brake warning switch black 2 1 c102 circuit cav 1 2 3 1 2 3 black circuit cav 1 2 3 l65 18lg/db l90 18db/rd z1 18bk l65 18lg/db l90...

  • Page 1482

    8w - 80 - 12 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08012 circuit - cav 1 2 3 4 5 6 7 8 9 10 11 12 13 14 l53 20br z1 18bk z2 18bk/or d2 18wt/bk d1 18vt/br t106 20gy/or t107 20bk/rd v32 20yl/rd l50 18wt/tn c13 16db/rd g28 20lg/or k167 20br/yl k900 20pk/bk c132 (diesel) c132 (diesel) circuit - cav...

  • Page 1483

    Zg-rhd 8w - 80 - 13 8w-80 connector pin-outs j978w-3 zgr08013 circuit - cav 1 2 3 4 5 6 7 8 9 10 c2 18db/yl d83 20bk/pk k95 20pk c21 18db/or t40 12lb/bk k95 20pk v32 20yl/rd c21 18db/or t40 12lg/bk circuit - - - - cav 1 2 3 4 5 6 7 8 9 10 c2 18db/yl d83 20bk/wt d84 20bk/wt k95 20pk c21 18db/or t40 1...

  • Page 1484

    8w - 80 - 14 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08014 circuit - - - - - - - - cav a b c d e f g h j k l m n p r s c7 12bk/tn c6 14lb c5 14lg c4 14tn c36 20db/rd f71 20pk/dg c34 20vt/wt c1 14dg c206 (with manual a/c heater) c206 (with manual a/c heater) circuit - - - - - - - - cav a b c d e f...

  • Page 1485

    Zg-rhd 8w - 80 - 15 8w-80 connector pin-outs j978w-3 zgr08015 * gas ** diesel circuit cav a b g28 20lg/or 107 20bk/rd circuit cav a b g42 20lg/rd t10 20yl/bk c212 c212 circuit cav 1 2 a41 14yl t141 14yl/rd circuit cav 1 2 t141 14yl/rd t141 14yl/rd c229 c229 (manual trans only) circuit - cav 1 2 3 4 ...

  • Page 1486

    Zg-rhd 8w - 80 - 16 8w-80 connector pin-outs j978w-3 zgr08016 circuit cav f1 f2 f3 f4 f5 f5 f6 f6 f7 f8 f8 f9 f9 f10 f11 f12 f12 f12 f13 f13 f14 f15 f15 f17 f18 f19 f19 f20 v11 18tn/bk l3 16rd/or l4 16vt/or v4 18rd/yl g9 16gy/bk* g9 18gy/bk** g18 16pk/bk* g118 16pk/db** g29 16bk/tn k4 20bk/lb* k4 18...

  • Page 1487

    Zg-rhd 8w - 80 - 17 8w-80 connector pin-outs j978w-3 zgr08017 circuit - - - - - - - - cav h1 h2 h3 h4 h5 h6 h7 h8 h9 h10 h11 h12 h13 h14 h15 h16 h17 h18 l101 20rd l102 20wt l103 20lb l104 20lg l105 20pk l106 20yl f99 20or** z1 18bk z2 18bk/or k4 20bk/lb** c236 circuit - - - - - - - - - cav h1 h2 h3 ...

  • Page 1488

    Zg-rhd 8w - 80 - 18 8w-80 connector pin-outs j978w-3 zgr08018 circuit - - - - - - cav 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 g9 20gy/bk b1 20yl/db b2 20yl b41 20yl/vt b42 20tn/wt b43 20pk/or g40 18lb/bk b3 20lg/db b4 20lg k167 20br/yl l50 18wt/tn a64 16dg/wt c304 circuit - - - - cav 2 2 2 3 4 ...

  • Page 1489

    8w - 80 - 19 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08019 circuit - - - - - - - cav 1 2 3 4 5 6 7 8 9 10 11 12 13 14 v24 18br/or v20 18bk/wt x55 16br/rd x55 16br/rd x53 16dg x53 16dg x54 16vt x54 16vt x56 16db x56 16db z5 14bk/lb z5 14bk/lb x51 16br/yl x51 16br/yl x57 16br/lb x57 16br/lb l50 18w...

  • Page 1490

    Zg-rhd 8w - 80 - 20 8w-80 connector pin-outs j978w-3 zgr08020 circuit cav 1 2 3 4 5 5 6 l74 18pk/bk l22 18lb l10 18br/lg z1 18bk l60 18tn l60 18tn l36 18lg/or c320 circuit cav 1 2 3 4 5 6 l74 18pk/bk l21 18lb/wt l10 18br/lg z1 18bk l61 18lg l36 18lg/bk c320 circuit - - - cav 1 2 3 4 5 6 g71 20vt/yl ...

  • Page 1491

    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...

  • Page 1493

    8w - 80 - 23 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08023 circuit - - cav 1 2 3 4 5 6 6 7 8 8 9 10 11 12 13 14 z1 12bk f81 10tn e21 18or/rd q17 14db/wt x53 16dg** x87 16lg/rd* q27 14rd/bk x55 16br/rd** x85 16lg/bk* p114 18yl/bk p112 18yl/wt d2 18wt/bk d1 18vt/br g71 20vt/yl circuit - - cav 1 2 3...

  • Page 1494

    Zg-rhd 8w - 80 - 24 8w-80 connector pin-outs j978w-3 zgr08024 circuit - - - cav a a b b c d e f g h x94 16tn/rd* x52 16db/wt** x92 16tn/bk* x58 16db/or** p2 16bk/wt z1 16bk e20 18or/db circuit - - - cav a b c d e f g h x52 20db/wt x58 20db/or p2 18bk/wt z1 16bk e20 20or/dg c345 black a h d e black a...

  • Page 1495

    Zg-rhd 8w - 80 - 25 8w-80 connector pin-outs j978w-3 zgr08025 black black a b a b circuit cav a b l87 18dg/wt z1 18bk circuit cav a b l87 20dg/wt z1 20bk c359 circuit cav a b z1 20bk l90 20db/rd circuit cav a b z1 20bk l90 20db/rd c364 black b a black a b c359 c364 black 1 4 black 1 4 circuit cav 1 ...

  • Page 1496

    8w - 80 - 26 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08026 circuit function 5 volt supply sensor ground camshaft position sensor signal cav 1 2 3 k25 20wt/bk k4 20bk/lb k24 18gy/bk black camshaft position sensor 4.0l, 5.2l (gas) 1 3 circuit function courtesy lamp relay output fused b(+) liftgate ...

  • Page 1497

    Zg-rhd 8w - 80 - 27 8w-80 connector pin-outs j978w-3 zgr08027 circuit function ignition switch output start clutch interlock switch sense cav 1 2 a41 14yl t141 14yl clutch interlock switch (diesel) (manual trans) 1 2 black circuit function stop lamp switch output stop lamp switch output ground groun...

  • Page 1498

    Zg-rhd 8w - 80 - 28 8w-80 connector pin-outs j978w-3 zgr08028 circuit - - - - - - - - function - - - - - - - - ccd bus(+) ground ground sci transmit sci recieve ccd bus (-) sci transmit fused b(+) cav 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 d1 18vt/br z1 18bk z2 18bk/or d84 20bk/wt d83 20bk/pk d2 18w...

  • Page 1499

    Zg-rhd 8w - 80 - 29 8w-80 connector pin-outs j978w-3 zgr08029 circuit function ground courtesy lamp relay output fused b(+) cav a b c z1 20bk m2 2oyl m1 20pk dome/reading lamp natural a c circuit function left front window driver (up) left front window driver (down) left rear window driver (up) left...

  • Page 1500

    Zg-rhd 8w - 80 - 30 8w-80 connector pin-outs j978w-3 zgr08030 d a circuit function ground 5 volt supply set led driver switched mux led supply cav a b c d z1 20bk p22 20br g49 20or m1 20gy black driver door module - c3 circuit function ground heated seat driver cav a b z1 16bk p88 16br/bk black driv...

  • Page 1501

    8w - 80 - 31 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08031 circuit function sensor ground front riser position sense 6 volt sensor supply cav a b c p28 20br/rd p26 20br p29 20br/wt black driver power seat front riser motor sensor a c driver power seat horizontal motor black 2 1 circuit function h...

  • Page 1502

    Zg-rhd 8w - 80 - 32 8w-80 connector pin-outs j978w-3 zgr08032 circuit function lumbar rearward switch sense lumbar forward driver ground fused b(+) ground lumbar forward switch sense lumbar forward switch sense lumbar reward driver cav 1 1 2 3 4 5 5 p104 20yl/rd* p107 18or/bk z1 18bk f35 18rd z1 18b...

  • Page 1503

    8w - 80 - 33 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08033 circuit function 6 volt sensor supply horizontal position sense sensor ground cav a b c p29 20br/wt p47 20lb p28 20br/rd black driver power seat recliner motor sensor c a circuit function ground recliner up switch sense recliner up driver...

  • Page 1504

    Zg-rhd 8w - 80 - 34 8w-80 connector pin-outs j978w-3 zgr08034 2 1 driver side airbag yellow circuit function driver air bag line 2 driver air bag line 1 cav 1 2 r45 18dg/lb r43 18bk/lb circuit function ignition switch output (start/run) evaporative emission solenoid control cav 1 2 f99 20or k52 18pk...

  • Page 1505

    8w - 80 - 35 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08035 * gas ** diesel circuit function b(+) b(+) engine starter motor relay output engine starter motor relay output cav 1 1 2 2 a0 6rd a0 2rd** t40 12lg/bk t40 14lg/bk** engine starter motor black 1 2 circuit - function - fused ignition switch...

  • Page 1506

    8w - 80 - 36 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08036 circuit function sleeve position sensor (-) cont sleeve position sensor sleeve position sensor (+) sensor ground fuel timing shutoff solenoid shutoff feed fuel temp sensor signal fuel quantity actuator ground auto shutdown relay output au...

  • Page 1507

    8w - 80 - 37 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08037 circuit function g switch ground g switch no. 1 sense g switch no. 2 sense cav 1 2 3 b43 20pk/or b41 20yl/vt b42 20tn/wt g-switch circuit - function - automatic shut down relay output generator field driver cav 1 2 3 a142 16dg/or k20 18dg...

  • Page 1508

    1 2 3 4 5 6 7 8 8w - 80 - 38 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08038 circuit - - - function - - - engine coolant level switch sense fused b(+) ground turn signal rear lamp out indicator driver ccd bus (+) ccd bus (-) panel lamp driver park lamp relay output washer fluid level sense 4-wheel ...

  • Page 1509

    8w - 80 - 39 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08039 circuit - - - function - - - panel lamp driver ground switched courtesy lamp feed fog lamp relay output ground fog lamp switch output coil driver #6 panel lamp dimmer switch signal fused b(+) low headlamp switch sense auto headlamp switch...

  • Page 1510

    8w - 80 - 40 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08040 circuit function idle air control no. 1 driver idle air control no. 3 driver idle air control no. 4 driver idle air control no. 2 driver cav 1 2 3 4 k39 16gy/rd k40 16br/wt k59 16vt/bk k60 16yl/bk idle air control motor (5.2l v-8) black 4...

  • Page 1511

    8w - 80 - 41 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08041 circuit function automatic shut down relay output injector no.1 driver cav 1 2 a142 18dg/or k11 18wt/db circuit function automatic shut down relay output injector no. 2 driver cav 1 2 a142 18dg/or k12 18tn gray 2 fuel injector no.1 1 gray...

  • Page 1512

    8w - 80 - 42 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08042 circuit function automatic shut down relay output injector no. 6 driver cav 1 2 a142 18dg/or k58 18br/yl gray 2 fuel injector no.6 1 circuit function automatic shut down relay output injector no. 7 driver cav 1 2 a142 18dg/or k17 18db/wt ...

  • Page 1513

    8w - 80 - 43 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08043 junction block - c3 circuit - - - - function - - - - horn relay control 2-wheel drive lamp/low range fog lamp relay output fused b(+) fused b(+) park lamp switch output turn signal switch output fused ignition switch output (acc/run) cav ...

  • Page 1514

    8w - 80 - 44 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08044 junction block - c6 3 1 4 2 black circuit function fused ignition switch output (acc/run) fused ignition switch output (start/run) rear window defogger relay output fused b(+) cav 1 2 3 4 a31 12rd/bk a21 12db/gy c15 12bk/wt f61 16wt/or ju...

  • Page 1515

    8w - 80 - 45 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08045 8 3 1 12 7 2 junction block - c9 light gray circuit - - - function - - - rear window defogger lamp driver fused b(+) fused ignition switch output (run) fused b(+) fused ignition switch output (start/run) fused ignition switch output (run)...

  • Page 1516

    8w - 80 - 46 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08046 black 1 3 6 7 10 2 junction block body connector - c14 circuit - - function - - back-up lamp switch output fused ignition switch output (start/run) courtesy lamp relay output radio 12 volt output fused b(+) fused b(+) fused b(+) fused b(+...

  • Page 1517

    8w - 80 - 47 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08047 circuit - function - not used not used stop lamp switch output park lamp relay output park lamp relay output park lamp switch output park lamp switch output stop lamp switch output stop lamp switch output stop lamp switch output ground ca...

  • Page 1518

    8w - 80 - 48 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08048 circuit function back-up lamp switch output ground cav a g l10 18br/lg z1 18bk black left back-up lamp a g circuit function fused b(+) courtesy lamp relay output cav a b m1 20pk m2 20yl left courtesy lamp black circuit function fused b(+)...

  • Page 1519

    8w - 80 - 49 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08049 circuit function left front door unlock driver left front door lock driver cav 1 2 p34 18pk/bk p35 18or/vt black 2 1 left front door lock motor circuit function left front (+) left front (-) cav a b x53 20dg x55 20br/rd b left front door ...

  • Page 1520

    8w - 80 - 50 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08050 black left front turn signal lamp a g circuit function turn signal switch output ground cav a g l64 18tn/db z1 18bk circuit function left front wheel speed sensor (-) left front wheel speed sensor (+) cav 1 2 b8 20rd/db b9 20rd left front...

  • Page 1521

    8w - 80 - 51 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08051 circuit function park lamp relay output ground cav 1 2 l90 20db/rd z1 20bk natural left license lamp 1 2 circuit function park lamp relay ground cav 1 2 l90 18db/rd z1 18bk left park lamp circuit function door unlock driver door lock driv...

  • Page 1522

    8w - 80 - 52 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08052 circuit function left rear window driver (up) left rear window driver (up) left rear door switch illumination left rear window driver (down) left rear window driver (down) ground cav 1 2 3 4 5 6 q18 16gy/bk q12 16br e20 20or/dg q28 16dg/w...

  • Page 1523

    8w - 80 - 53 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08053 circuit function stop lamp switch output park lamp switch output ground cav a b g l74 18pk/bk l21 18lb/wt z1 18bk black b a g left tail/stop lamp circuit function fused b(+) ground cav a b m1 20pk z1 20bk a left visor/ vanity mirror black...

  • Page 1524

    8w - 80 - 54 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08054 circuit - function - ground liftglass ajar switch sense cav 1 2 3 z1 20bk g78 20tn/bk 1 liftglass ajar switch black 3 circuit function fused b(+) liftglass limit switch output cav a b f70 16pk/bk p101 16or/pk a liftglass limit switch natu...

  • Page 1525

    8w - 80 - 55 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08055 circuit function ground sensor ground fused (b+) air flow meter signal cav 1 2 3 4 z1 20bk k4 20bk/lb a142 18dg/or k155 20db mass air flow module circuit function power ground tachometer signal wait to start lamp fuel quantity actuator gr...

  • Page 1526

    8w - 80 -56 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08056 circuit - function - 6 volt sensor supply sensor ground horizontal position sense front riser position sense rear riser position sense recliner position sense lumbar position sense front riser down switch sense front riser up switch sense ...

  • Page 1527

    8w - 80 - 57 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08057 circuit function fused ignition switch output (run) ground ccd bus(+) courtesy lamp relay output ccd bus(-) fused b(+) cav 1 2 3 4 5 6 f83 20yl/dg z1 20bk d1 18vt/br m2 20yl d2 18wt/bk m1 20pk mini overhead console red 3 4 1 6 circuit fun...

  • Page 1528

    8w - 80 - 58 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08058 circuit function sensor ground oil pressure sensor signal oil pressure sensor signal sensor return cav 1 1 2 2 k4 20bk/lb g60 20gy/yl* g6 18gy/wt k167 20br/yl* black oil pressure sensor 2 1 circuit function output shaft speed sensor signa...

  • Page 1529

    8w - 80 - 59 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08059 circuit function back-up lamp switch output park/neutral position switch sense fused ignition switch output (run) cav 1 2 3 l10 18br/lg t41 20bk/wt f83 18yl/dg black park/neutral position switch 1 3 circuit function passenger airbag line ...

  • Page 1530

    8w - 80 - 60 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08060 circuit function ground heated seat driver cav a b z1 16bk p88 16br/bk green passenger heated seat back a b circuit function heated seat driver heated seat driver passenger heated seat switch output ground cav a b c d p87 16bk/or p88 16br...

  • Page 1531

    8w - 80 - 61 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08061 circuit function front riser down switch sense front riser up switch sense cav 1 2 p20 16rd/lg p18 16yl/lg red passenger power seat front riser motor 1 2 circuit function horizontal forward switch sense horizontal rearward switch sense ca...

  • Page 1532

    8w - 80 - 62 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08062 passenger seat heater control module circuit - - - function - - - fused ignition switch output fused b(+) heated seat driver ground passenger heated seat switch output cav 1 2 3 4 5 6 7 8 f87 18wt/bk f35 16rd p87 16bk/or z1 18bk p8 18lb/w...

  • Page 1533

    8w - 80 - 63 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08063 circuit - - - - - function - - - - fused b(+) power amplifier radio ground right front speaker(-) left front speaker (-) right rear speaker(-) left rear speaker(-) left rear speaker (+) right rear speaker (+) left front speaker (+) right ...

  • Page 1534

    8w - 80 - 64 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08064 circuit function fused b(+) ground cav 1 2 f38 18or z1 18bk power outlet black 2 1 fused ignition switch output (start/run) sensor ground park neutral position switch sense ignition coil no. 1 driver crankshaft position sensor signal idle...

  • Page 1535

    8w - 80 - 65 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08065 transmission temperature sensor signal injector no. 7 driver injector no. 1 driver injector no. 3 driver injector no. 5 driver variable force solenoid control generator field driver torque converter clutch solenoid control injector no. 6 ...

  • Page 1536

    8w - 80 - 66 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08066 a/c compressor clutch relay control automatic shut down relay control speed control vacuum solenoid control speed control vent solenoid control overdrive off lamp driver vapor canister solenoid driver speed control on/off switch sense aut...

  • Page 1537

    8w - 80 - 67 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08067 low fuel warning fused b(+) sensor ground 5 volt supply coolant level sensor fused ignition switch output ground ground generator field driver engine coolant temperature sensor signal throttle position sensor signal water-in-fuel sense di...

  • Page 1538

    8w - 80 - 68 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08068 circuit - function - left front (-) right front (-) park lamp relay output panel lamp driver fused ignition switch output (acc/run) fused b(+) cav 1 2 3 4 5 6 7 x55 20br/rd x56 20db l90 20db/rd e2 20or x12 18rd/gy f60 20rd/wt radio - c1 g...

  • Page 1539

    8w - 80 - 69 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08069 rear washer pump motor black circuit function rear washer motor control ground cav 1 2 v20 18wt/bk z2 18bk 1 2 circuit function fused (b+) rear wiper motor control ground rear wiper motor control (int) rear washer motor control liftgate a...

  • Page 1540

    8w - 80 - 70 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08070 circuit function right impact sensor line 1 right impact sensor line 2 cav 1 2 r46 18br/lb r48 18tn right airbag sensor black 2 1 circuit function back-up lamp switch output ground cav a g l10 18br/lg z1 18bk black right back-up lamp a g ...

  • Page 1541

    8w - 80 - 71 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08071 circuit function vtss disarm sense ground cav 1 2 g71 20vt/yl z1 20bk black 2 1 right front cylinder lock switch circuit function door unlock driver door lock driver cav 1 2 p34 14pk/bk p2 14bk/wt black 2 1 right front door lock motor cir...

  • Page 1543

    8w - 80 - 73 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08073 circuit function park lamp relay output ground cav 1 2 l90 20db/rd z1 20bk natural right license lamp 1 2 circuit function door unlock driver door lock driver cav 1 2 p34 18pk/bk p2 18bk/wt right rear door lock motor black 1 2 circuit fun...

  • Page 1544

    8w - 80 - 74 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08074 circuit function ground park lamp switch output cav 1 2 z1 18bk l22 18lb natural right rear side marker lamp 1 2 circuit function turn signal switch output ground cav a g l61 18lg z1 18bk black right rear turn signal lamp a g function cir...

  • Page 1545

    8w - 80 - 75 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08075 circuit function fused b(+) ground cav a b m1 20pk z1 20bk a right visor/ vanity mirror black b circuit function seat belt switch sense ground cav 1 2 g10 20lg/rd z1 20bk seat belt switch circuit function shift interlock solenoid sense fu...

  • Page 1546

    8w - 80 - 76 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08076 speed proportional steering module green circuit - - - function - - - speed proportional steering solenoid control low speed proportional steering solenoid control high steering wheel speed sensor ground 5 volt supply vehicle speed sensor...

  • Page 1547

    8w - 80 - 77 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08077 steering wheel speed sensor circuit function 5 volt supply steering wheel speed sensor ground steering wheel speed sensor signal a steering wheel speed sensor signal b cav a b c d s1 20bk/yl s2 20bk/lg s3 20pk/wt s4 20vt a d natural circu...

  • Page 1548

    8w - 80 - 78 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08078 circuit function 5 volt supply throttle position sensor signal sensor ground cav *1 *2 *3 k25 20wt/bk k22 18or/db k4 20bk/lb black throttle position sensor 3 2 1 circuit function fused b(+) fused b(+) cav a b f70 16pk/bk f70 16pk/bk black...

  • Page 1549

    8w - 80 - 79 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08079 circuit function stop lamp switch output ground fused b(+) factory trailer tow relay outputs factory trailer tow relay outputs cav 1 2 3 4 5 l50 18wt/tn z1 18bk f70 16pk/bk 94 18dg 95 18pk trailer tow stop lamp relay black 3 5 2 4 1 circu...

  • Page 1550

    8w - 80 - 80 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08080 circuit function speed control vacuum solenoid control speed control vent solenoid control speed control stop lamp switch output ground cav 1 2 3 4 v36 18tn/rd v35 18lg/rd v30 20db/lg z4 20bk vehicle speed control servo black 1 4 circuit ...

  • Page 1551

    8w - 80 - 81 zg-rhd 8w-80 connector pin-outs j978w-3 zgr08081 circuit function washer switch output ground cav a b v11 18tn/bk z2 18bk circuit - function - fused ignition switch output (acc/run) wiper park switch sense ground wiper switch low speed output wiper switch high speed output cav 1 2 3 4 5...

  • Page 1553

    8w-90 connector locations description and operation introduction this section provides illustrations identifying com- ponent and connector locations in the vehicle. A con- nector index is provided. Use the wiring diagrams in each section for connector number identification. Refer to the index for th...

  • Page 1554

    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 connect...

  • Page 1555

    Connector name/number color location fig. Downstream heated oxygen sensor bk above rear of catalytic converter 7, 10 driver door module c1 wt in left front door 20 driver door module c2 bk in driver’s door n/s driver door module c3 bk in driver’s door n/s driver heated seat back bk under driver’s se...

  • Page 1556

    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 driver’s seat 18 g302 on floor pan rear of seat 19 g303 on floor pan rear of seat 19 g304 on floor pan rear of seat 19 g305 on floor...

  • Page 1557

    Connector name/number color location fig. Lamp outage module c2 bk left rear quarter panel, near bottom of liftgate opening 19 left back-up lamp bk at lamp n/s left courtesy lamp bk at lamp 14 left door courtesy lamp bk in left front door 20 left fog lamp bk left fog lamp 1 left front cylinder lock ...

  • Page 1558

    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...

  • Page 1559

    Connector name/number color location fig. Right headlamp leveling motor bk at headlamp 1 right instrument panel speaker bk top right of instrument panel 14 right license lamp nat in liftgate, behind license plate lamps 25 right rear door lock motor bk in right rear door 21 right rear door speaker bk...

  • Page 1560

    Fig. 1 front end lighting 8w - 90 - 8 8w - 90 connector locations zg description and operation (continued).

  • Page 1561

    Fig. 2 engine compartment—right side zg 8w - 90 connector locations 8w - 90 - 9 description and operation (continued).

  • Page 1562

    Fig. 3 engine compartment 8w - 90 - 10 8w - 90 connector locations zg description and operation (continued).

  • Page 1563

    Fig. 4 engine compartment left side zg 8w - 90 connector locations 8w - 90 - 11 description and operation (continued).

  • Page 1564

    Fig. 5 engine connectors—4.0l engine 8w - 90 - 12 8w - 90 connector locations zg description and operation (continued).

  • Page 1565

    Fig. 6 charging system connectors—4.0l engine zg 8w - 90 connector locations 8w - 90 - 13 description and operation (continued).

  • Page 1566

    Fig. 7 t ransmission connectors—4.0l engine 8w - 90 - 14 8w - 90 connector locations zg description and operation (continued).

  • Page 1567

    Fig. 8 engine connectors—5.2l engine zg 8w - 90 connector locations 8w - 90 - 15 description and operation (continued).

  • Page 1568

    Fig. 9 engine connectors—5.2l engine 8w - 90 - 16 8w - 90 connector locations zg description and operation (continued).

  • Page 1569

    Fig. 10 t ransmission connectors—5.2l zg 8w - 90 connector locations 8w - 90 - 17 description and operation (continued).

  • Page 1570

    Fig. 1 1 engine connectors—diesel engine 8w - 90 - 18 8w - 90 connector locations zg description and operation (continued).

  • Page 1571

    Fig. 12 battery and starter motor connectors—diesel engine zg 8w - 90 connector locations 8w - 90 - 19 description and operation (continued).

  • Page 1572

    Fig. 13 t ransmission connectors—diesel engine 8w - 90 - 20 8w - 90 connector locations zg description and operation (continued).

  • Page 1573

    Fig. 14 instrument panel connectors zg 8w - 90 connector locations 8w - 90 - 21 description and operation (continued).

  • Page 1574

    Fig. 15 instrument panel connectors 8w - 90 - 22 8w - 90 connector locations zg description and operation (continued).

  • Page 1575

    Fig. 16 steering column connectors zg 8w - 90 connector locations 8w - 90 - 23 description and operation (continued).

  • Page 1576

    Fig. 17 roof connectors 8w - 90 - 24 8w - 90 connector locations zg description and operation (continued).

  • Page 1577

    Fig. 18 body connectors—right side zg 8w - 90 connector locations 8w - 90 - 25 description and operation (continued).

  • Page 1578

    Fig. 19 body connectors—left side 8w - 90 - 26 8w - 90 connector locations zg description and operation (continued).

  • Page 1579

    Fig. 20 front door connectors zg 8w - 90 connector locations 8w - 90 - 27 description and operation (continued).

  • Page 1580

    Fig. 21 rear door connectors 8w - 90 - 28 8w - 90 connector locations zg description and operation (continued).

  • Page 1581

    Fig. 22 factory t railer t o w zg 8w - 90 connector locations 8w - 90 - 29 description and operation (continued).

  • Page 1582

    Fig. 23 liftgate connectors 8w - 90 - 30 8w - 90 connector locations zg description and operation (continued).

  • Page 1583

    Fig. 24 underhood lamp fig. 25 license plate lamps zg 8w - 90 connector locations 8w - 90 - 31 description and operation (continued).

  • Page 1585

    8w-95 splice locations description and operation introduction this section provides illustrations identifying the general location of the splices in this vehicle. A splice index is provided. Use the wiring diagrams in each section for splice number identification. Refer to the index for proper splic...

  • Page 1586

    Splice number location fig. S134 near crankshaft position sensor t/o (diesel engine) 4 s135 near branch to pcm (4.0l engine) 2 s135 right rear of engine (5.2l engine) 3 s136 near injector no. 7 t/o (5.2l engine) 3 s136 near crankshaft position sensor t/o (diesel engine) 4 s138 near crankshaft positi...

  • Page 1587

    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 s...

  • Page 1588

    Fig. 1 engine compartment splices 8w - 95 - 4 8w - 95 splice locations zg description and operation (continued).

  • Page 1589

    Fig. 2 engine w iring splices—4.0l engine zg 8w - 95 splice locations 8w - 95 - 5 description and operation (continued).

  • Page 1590

    Fig. 3 engine w iring splices—5.2l engine 8w - 95 - 6 8w - 95 splice locations zg description and operation (continued).

  • Page 1591

    Fig. 4 engine and t ransmission w iring splices—diesel engine zg 8w - 95 splice locations 8w - 95 - 7 description and operation (continued).

  • Page 1592

    Fig. 6 body splices fig. 7 hvac harness splices 8w - 95 - 8 8w - 95 splice locations zg description and operation (continued).

  • Page 1593

    Fig. 5 instrument panel splices 8w - 95 - 8 8w - 95 splice locations zg description and operation (continued).

  • Page 1594

    Fig. 8 left body side w iring splices 8w - 95 - 10 8w - 95 splice locations zg description and operation (continued).

  • Page 1595

    Fig. 10 roof wiring splices fig. 11 front door harness splices zg 8w - 95 splice locations 8w - 95 - 11 description and operation (continued).

  • Page 1596

    Fig. 9 right side body w iring splices zg 8w - 95 splice locations 8w - 95 - 11 description and operation (continued).

  • Page 1597

    Fig. 12 liftgate splices zg 8w - 95 splice locations 8w - 95 - 13 description and operation (continued).

  • Page 1599: Engine

    Engine contents page page 4.0l engine . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5.2l engine . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.9l engine . . . . . . . . . . . . . . . . . . . . . . . . . . 89 engine diagnosis . . . . . . . . . . . . . . . . . . . . . . 8 standard s...

  • Page 1600

    Gasket application assembling parts using a form-in-place gasket requires care. Mopar t silicone rubber adhesive sealant should be applied in a continuous bead approximately 3 mm (0.12 inch) in diameter. All mounting holes must be circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4 inch) drop is pl...

  • Page 1601

    (1) used carefully, the cylinder bore sizing hone c-823 equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes will clean up a bore and maintain the ...

  • Page 1602

    Or the plastigage may be smeared, giving inac- curate results. (2) remove the bearing cap and compare the width of the flattened plastigage with the scale provided on the package (fig. 3). Plastigage generally comes in 2 scales (one scale is in inches and the other is a met- ric scale). Locate the b...

  • Page 1603

    Hydrostatic lock when an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below. (1) perform the fuel pressure release procedure (refer to group 14, fuel system). (2) disconnect the negative cable from the battery. (3) inspect air cleaner, induction s...

  • Page 1604

    Oil level indicator (dipstick) the engine oil level indicator is located at the right rear of engine on 4.0l engines (fig. 6) and the right front of the engine on 5.2/5.9l engines (fig. 7). Crankcase oil level inspection caution: do not overfill crankcase with engine oil, oil foaming and oil pressur...

  • Page 1605

    (7) lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec- tion. (8) install oil fill cap. (9) start engine and inspect for leaks. (10) stop engine and inspect oil level. Engine oil filter change filter specification all engines are equipped with a high ...

  • Page 1606

    Engine diagnosis index page page diagnosis and testing cylinder combustion pressure leakage test . . . . . . . . . . . . . . . . . . . . . . . 9 cylinder compression pressure test . 8 engine cylinder head gasket failure diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 8 engine oil press...

  • Page 1607

    Dures outlined in cylinder compression pressure test. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure. Cylinder-to-water jacket leakage test warning: use extreme caution when the engine is operating. Do not sta...

  • Page 1608

    Approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light. (3) using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and ...

  • Page 1609

    Which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may ...

  • Page 1610

    Engine—performance condition possible causes correction engine will not start 1. Weak battery. 1. Test battery specific gravity. Charge or replace as necessary. 2. Corroded or looose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals....

  • Page 1611

    Engine—mechanical condition possible causes correction noisy valves 1. High or low oil level in crankcase. 1. Check for correct oil level (refer to group 0, lubrication and maintenance.) 2. Thin or diluted oil. 2. Change oil (refer to group 0, lubrication and maintenance). 3. Low oil pressure. 3. Ch...

  • Page 1612

    Engine—lubrication condition possible causes correction oil leaks 1. Gaskets and o-rings. 1. (a) misaligned, deteriorated or torn. (a) replace the part. (b) loose fastener, broken or porous metal part. (b) tighten, repair or replace the part. 2. Crankshaft rear seal 2. (a) misinstalled, inverted or ...

  • Page 1613

    4.0l engine index page page description and operation engine description . . . . . . . . . . . . . . . . . . 15 lubrication system . . . . . . . . . . . . . . . . . . 16 oil pump pressure . . . . . . . . . . . . . . . . . . . 16 oversize and undersize component codes . . . . . . . . . . . . . . . . ...

  • Page 1614

    The crankshaft rotation is clockwise, when viewed from the front of the engine. The crankshaft rotates within seven main bearings. The camshaft rotates within four bearings. Build date code the engine build date code is located on a machined surface on the right side of the cylinder block between th...

  • Page 1615

    Oil lubrication system oil gallery camshaft bearing number 1 camshaft bearing journal camshaft sprocket zg 4.0l engine 9 - 17 description and operation (continued).

  • Page 1616

    Oversize and undersize component codes some engines may be built with oversize or under- size components such as: • oversize cylinder bores. • oversize camshaft bearing bores. • undersize crankshaft main bearing journals. • undersize connecting rod journals. These engines are identified by a letter ...

  • Page 1617

    Must be replaced as complete sets. Tin coated pistons should not be used as replacements for coated pistons. (4) the coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not pro- vide accurate results (fig. 5). The...

  • Page 1618

    Ring side clearance measurement top compression ring . . . . . . . . . 0.042 to 0.084 mm (0.0017 to 0.0033 in.) second compression ring . . . . . . 0.042 to 0.084 mm (0.0017 to 0.0033 in.) oil control ring . . . . . . . . . . . . . . . 0.06 to 0.21 mm (0.0024 to 0.0083 in.) (4) place ring in the cyl...

  • Page 1619

    Ring gap orientation • position the gaps on the piston as shown (fig. 14). • oil spacer - gap on center line of piston skirt. • oil rails - gap 180° apart on centerline of piston pin bore. • no. 2 compression ring - gap 180° from top oil rail gap. • no. 1 compression ring - gap 180° from no. 2 compr...

  • Page 1620

    Bearing-to-journal clearance (1) wipe the oil from the connecting rod journal. (2) use short rubber hose sections over rod bolts during installation. (3) lubricate the upper bearing insert and install in connecting rod. (4) use piston ring compressor to install the rod and piston assemblies. The oil...

  • Page 1621

    Undersize inserts would reduce the clearance by 0.025 mm (0.001 inch). The clearance would be 0.002 inch and within specification. A 0.051 mm (0.002 inch) undersize insert would reduce the initial clear- ance an additional 0.013 mm (0.0005 inch). The clearance would then be 0.038 mm (0.0015 inch). (...

  • Page 1622

    The main bearing journal size (diameter) is identi- fied by a color-coded paint mark (fig. 21) on the adjacent cheek or counterweight towards the rear of the crankshaft (flange end). The rear main journal, is identified by a color-coded paint mark on the crank- shaft rear flange. When required, uppe...

  • Page 1623

    The clearance indicate with the 0.025 mm (0.001 inch) undersize insert pair installed will determine if this insert size or some other combination will pro- vide the specified clearance. For example: if the clearance was 0.762 mm (0.003 inch) originally, a pair of 0.0254 mm (0.001 inch) undersize in...

  • Page 1624

    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 0.02...

  • Page 1625

    Removal and installation engine mounts—front the front mounts support the engine at each side. These insulators are made of resilient rubber. Removal (1) disconnect the negative cable from the battery. (2) support the engine. (3) raise the vehicle. (4) remove the insulator assembly-to-lower front si...

  • Page 1626

    (4) raise the transmission slightly. (5) remove the thru-bolt and nut. Remove the rear mount assy (fig. 26) (fig. 27). (6) if necessary, remove the bolts holding the rear mount bracket to the transmission. Remove the bracket from the exhaust pipe hanger. Remove the bracket. Installation (1) position...

  • Page 1627

    (16) disconnect injection system wire harness con- nector at each injector. Mark the wires for proper installation. (17) disconnect the distributor electrical connec- tion and the oil pressure switch connector. (18) disconnect the quick-connect fuel lines at the fuel rail and return line by squeezin...

  • Page 1628

    Installation, it may be necessary to remove the engine mount bracket as an aid in alignment of the engine to the transmission. (2) vehicles with manual transmission: (a) insert the transmission shaft into the clutch spline. (b) align the engine flywheel housing with the engine. (c) install and tight...

  • Page 1629

    Gasket. The grommet and limiter are retained in the cylinder head cover. There are two cylinder head bolts that have a pin to locate the cylinder head cover gasket, they are located at position 8 and 9 (fig. 32) removal (1) disconnect negative cable from battery. (2) disconnect the crankcase ventila...

  • Page 1630

    Installation (1) lubricate the ball ends of the push rods with mopar engine oil supplement, or equivalent and install push rods in their original locations. Ensure that the bottom end of each push rod is centered in the tappet plunger cap seat. (2) using mopar engine oil supplement, or equiv- alent,...

  • Page 1631

    Removal (1) disconnect negative cable from battery. Warning: do not remove the cylinder block drain plugs or loosen the radiator drain cock with the system hot and pres- surized because serious burns from the coolant can occur. (2) drain the coolant and disconnect the hoses at the engine thermostat ...

  • Page 1632

    (a) tighten all bolts in sequence (1 through 14) to 30 n·m (22 ft. Lbs.) torque. (b) tighten all bolts in sequence (1 through 14) to 61 n·m (45 ft. Lbs.) torque. (c) check all bolts to verify they are set to 61 n·m (45 ft. Lbs.) torque. (d) tighten bolts in sequence: • bolts 1 through 10 to 149 n·m ...

  • Page 1633

    Removal (1) remove the engine cylinder head from the cyl- inder block. (2) use valve spring compressor tool md-998772a and compress each valve spring. (3) remove the valve locks, retainers, springs and valve stem oil seals. Discard the oil seals. (4) use a smooth stone or a jewelers file to remove a...

  • Page 1634

    Timing case cover removal (1) disconnect negative cable from battery. (2) remove the vibration damper. (3) remove the fan and hub assembly and remove the fan shroud. (4) remove the accessory drive brackets that are attached to the timing case cover. (5) remove the a/c compressor (if equipped) and ge...

  • Page 1635

    (12) install the serpentine drive belt and tighten to obtain the specified tension. (13) connect negative cable to battery. Timing chain and sprockets removal (1) disconnect negative cable from battery. (2) remove the fan and shroud. (3) remove the serpentine drive belt. (4) remove the crankshaft vi...

  • Page 1636

    (8) with the key installed in the crankshaft key- way, install the vibration damper, washer and bolt. Lubricate and tighten the bolt to 108 n·m (80 ft. Lbs.) torque. (9) install the serpentine drive belt and tighten to the specified tension (refer to group 7, cooling sys- tem for the proper procedur...

  • Page 1637

    (15) install the cylinder head and head bolts (refer to cylinder head r&i in this section for torque values and tightening sequence). (16) install the push rods. (17) install the rocker arms and pivot and bridge assemblies. Tighten each of the capscrews for each bridge alternately, one turn at a tim...

  • Page 1638

    (17) if the pin is a dowel-type pin, center-punch it. Ensure the exact center is located when center- punching the pin. Caution: cover the opened oil pan area to pre- vent metal chips from entering the pan. (18) drill into the pin center with a 4 mm (5/32 inch) drill bit. (19) insert a self-tapping ...

  • Page 1639

    (120 in. Lbs.) torque. Tighten the oil pan-to-cover 5/16 inch bolts to 18 n·m (156 in. Lbs.) torque. (15) remove the cover alignment tool and install a replacement oil seal into the cover. (16) install the vibration damper on the crank- shaft. (17) lubricate and tighten the damper bolt to 108 n·m (8...

  • Page 1640

    (7) rotate the crankshaft after tightening each main bearing cap to ensure the crankshaft rotates freely. (8) check crankshaft end play. Crankshaft end play is controlled by the thrust bearing which is flange and installed at the no.2 main bearing posi- tion. (a) attach a magnetic base dial indicato...

  • Page 1641

    (2) fabricate 4 alignment dowels from 1 1/2 x 1/4 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (fig. 53). (3) install two dowels in the timing case cover. Install the other two dowels in the cylind...

  • Page 1642

    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 assistant push the piston and con- necting rod assemblies up and through the top of the...

  • Page 1643

    (10) install the connecting rod bearing caps and inserts in the same positions 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) install the oil pan and gaskets as outlined in the installation pro...

  • Page 1644

    Bypass through a passage in the pump body to the inlet side of the pump. Oil pump removal or replacement will not affect the distributor timing because the distributor drive gear remains in mesh with the camshaft gear. Removal (1) drain the engine oil. (2) remove the oil pan. (3) remove the pump-to-...

  • Page 1645

    Clean all grime and gasket material from the engine cylinder head machined gasket surface. Inspect for cracks in the combustion chambers and valve ports. Inspect for cracks on the exhaust seat. Inspect for cracks in the gasket surface at each coolant passage. Inspect valves for burned, cracked or wa...

  • Page 1646

    (7) compare the measured valve guide bore diam- eter with specifications (7.95-7.97 mm or 0.313-0.314 inch). If the measurement differs from specification by more than 0.076 mm (0.003 inch), ream the guide bore to accommodate an oversize valve stem. Alternative method (1) use a dial indicator to mea...

  • Page 1647

    Assembly refer to the applicable sections for detailed instructions. (1) install the crankshaft. (2) install the connecting rods and the pistons through the top of the cylinder bores. (3) install the oil pump. (4) install the oil pan and gasket. (5) install the camshaft. (6) install the sprockets an...

  • Page 1648

    (1) place a 7.925-7.950 mm (0.312-0.313 inch) diameter ball bearing on the plunger cap of the tap- pet. (2) lift the ram and position the tappet (with the ball bearing) inside the tester cup. (3) lower the ram, then adjust the nose of the ram until it contacts the ball bearing. Do not tighten the he...

  • Page 1649

    Cylinder bore after the engine has been in use for a period of time. Honing—cylinder bore the honing operation should be closely coordinated with the fitting of pistons and rings. This will ensure specified clearances are maintained. Refer to standard service procedures in the begin- ning of this gr...

  • Page 1650

    Cylinder compression pressure ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7:1 pressure range . . . . . . . . . . . . . 827 to 1,034 kpa (120 to 150 psi) max. Variation between cylinders . . . . . . 206 kpa (30 psi) cylinder head combustion chamber . . . . . . . . . 52.22 to...

  • Page 1651

    Piston-to-pin clearance (preferred) . . . . . . . . . . . . . . . . . . . . . 0.013 mm (0.0005 in.) piston-to-pin connecting rod (press fit) . . . . . . . . . . . . . . 8.9 kn (2000 lbf.) oil pump gear-to-body clearance (radial) . 0.051 to 0.102 mm (0.002 to 0.004 in.) gear-to-body clearance (radial...

  • Page 1652

    Description torque spark plugs plugs . . . . . . . . . . . . . . . . . . . . .37 n·m (27 ft. Lbs.) starter motor mounting bolts . . . . . . . . . . . . .45 n·m (33 ft. Lbs.) thermostat housing bolts . . . . . . . . . . . . . . . . . . . .18 n·m (156 in. Lbs.) throttle body bolts . . . . . . . . . . ...

  • Page 1653

    5.2l engine index page page general information oil pump pressure . . . . . . . . . . . . . . . . . . . 56 piston and connecting rod assembly . 56 valves and valve springs . . . . . . . . . . . . 56 description and operation engine components . . . . . . . . . . . . . . . . . 60 engine description ....

  • Page 1654

    This engine is designed for unleaded fuel. Engine type . . . . . . . . . . . . . . . . . . . . . 90° v-8 ohv bore and stroke . . . 99.3 x 84.0 mm (3.91 x 3.31 in.) displacement . . . . . . . . . . . . . . . . . . . 5.2l (318 c.I.) compression ratio . . . . . . . . . . . . . . . . . . . . . . 9.1:1 t...

  • Page 1655

    Fig. 3 oil lubrication system zg 5.2l engine 9 - 57 description and operation (continued).

  • Page 1656

    Engine components cylinder head the alloy cast iron cylinder heads (fig. 4) are held in place by 10 bolts. The spark plugs are located in the peak of the wedge between the valves. The 5.2l cylinder head is identified by the foundry mark nh. Pistons all pistons are machined to the same weight, regard...

  • Page 1657

    (8) turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in cam- shaft sprocket. (9) lift sprockets and chain (keep sprockets tight against the chain in position as described). (10) slide both sprockets evenly over their respec- tive shafts and use a straightedge t...

  • Page 1658

    Should not exceed 0.246 mm (0.0097 inch) side clearance. (e) pistons with insufficient or excessive side clearance should be replaced. Fitting connecting rod bearings fit all rods on a bank until completed. Do not alternate from one bank to another, because connect- ing rods and pistons are not inte...

  • Page 1659

    Nal is 0.025 mm (0.001 in) undersize. M4 indicates that the no.4 main journal is 0.025 mm (0.001 in) undersize. R3 m2 indicates that the no.3 rod journal and the no.2 main journal are 0.025 mm (0.001 in) undersize. When a crankshaft is replaced, all main and con- necting rod bearings should be repla...

  • Page 1660

    (a) right side—install the sill bracket assem- bly onto the sill assembly (fig. 14). Install and tighten the bolts to 65 n·m (48 ft. Lbs.) torque. (b) left side—install the sill bracket assem- bly onto the sill assembly (fig. 15). Install and tighten the 2 top bolts to 65 n·m (48 ft. Lbs.) torque. I...

  • Page 1661

    (21) support automatic transmission with a trans- mission stand. This will assure that the torque con- verter will remain in proper position in the transmission housing. (22) remove bell housing bolts and inspection plate. Attach c-clamp on front bottom of transmis- sion torque converter housing to ...

  • Page 1662

    Rocker arms and push rods removal (1) disconnect spark plug wires by pulling on the boot straight out in line with plug. (2) remove cylinder head cover and gasket. (3) remove the rocker arm bolts and pivots (fig. 18). Place them on a bench in the same order as removed. (4) remove the push rods and p...

  • Page 1663

    Installation (1) position the new cylinder head gaskets onto the cylinder block. (2) position the cylinder heads onto head gaskets and cylinder block. (3) starting at top center, tighten all cylinder head bolts, in sequence, to 68 n·m (50 ft. Lbs.) torque (fig. 19). Repeat procedure, tighten all cyl...

  • Page 1664

    Hydraulic tappets removal (1) remove the air cleaner. (2) remove cylinder head cover, rocker assembly and push rods. Identify push rods to ensure installa- tion in original location. (3) remove intake manifold, yoke retainer and aligning yokes. (4) slide hydraulic tappet remover/installer tool c-412...

  • Page 1665

    (5) remove power steering pump (refer to group 19, steering). (6) remove vibration damper. (7) loosen oil pan bolts and remove the front bolt at each side. (8) remove the cover bolts. (9) remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket. (10) place a suitable...

  • Page 1666

    (9) install vibration damper. (10) install water pump and housing assembly using new gaskets (refer to group 7, cooling sys- tem). Tighten bolts to 41 n·m (30 ft. Lbs.) torque. (11) install power steering pump (refer to group 19, steering). (12) install the serpentine belt (refer to group 7, cooling...

  • Page 1667

    Being careful not to damage cam bearings with the cam lobes. Installation (1) lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block. Note: whenever an engine has been rebuilt, a new camshaft and/or new tappet...

  • Page 1668

    (2) position rear bearing in the tool. Install horse- shoe lock and by reversing removal procedure, care- fully drive bearing shell into place. (3) install remaining bearings in the same man- ner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the mai...

  • Page 1669

    Caution: this procedure must be followed when installing a new bushing or seizure to shaft may occur. (4) install the intake manifold (refer to group 11, exhaust system and intake manifold). Distributor installation note: before installing the distributor, the oil pump drive shaft must be aligned to...

  • Page 1670

    (8) install the drain plug. Tighten drain plug to 34 n·m (25 ft. Lbs.) torque. (9) install exhaust pipe. (10) connect the oxygen sensor. (11) install the oil filter. (12) if equipped with an oil level sensor, connect the sensor. (13) install the starter (refer to group 8b, battery/ starter/generator...

  • Page 1671

    (8) install rod caps. Be sure connecting rod, con- necting rod cap and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 n·m (45 ft. Lbs.) torque. (9) install the oil pan. (10) install the cylinder head. (11) install the engine into the vehicle. Cr...

  • Page 1672

    Front crankshaft oil seal the oil seal can be replaced without removing the timing chain cover provided the cover is not mis- aligned. (1) disconnect the negative cable from the battery. (2) remove vibration damper. (3) if front seal is suspected of leaking, check front oil seal alignment to cranksh...

  • Page 1673

    (2) lightly oil the new upper seal lips with engine oil. (3) install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (4) position the crankshaft into the cylinder block. (5) lightly oil the new lower seal lips with engine oil. (6) install the new lower...

  • Page 1674

    Enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. (10) immediately install the oil pan. Lower seal removal (1) remove the oil pan. (2) remove the oil pump from the rear main bear- ing cap. (3) remove the rear main bearing cap an...

  • Page 1675

    (3) it is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately. Disassembly and assembly hydraulic tappets caution: the plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the ori...

  • Page 1676

    Valves inspect the remaining margin after the valves are refaced (fig. 54). Valves with less than 1.190 mm (0.047 inch) margin should be discarded. Valve seats caution: do not un-shroud valves during valve seat refacing (fig. 55). (1) when refacing valve seats, it is important that the correct size ...

  • Page 1677

    Ing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by 2. This will give the spring load at test length. Fractional mea- surements are indicated on the table for finer adjust- ments. Refer to specifications to ...

  • Page 1678

    Inspection inspect all surfaces with a straightedge if there is any reason to suspect leakage. If out-of-flatness exceeds 0.00075 mm/mm (0.00075 inch/inch) times the span length in inches in any direction, either replace head or lightly machine the head surface. For example: a 305 mm (12 inch) span ...

  • Page 1679

    Measure thickness and diameter of outer rotor. If outer rotor thickness measures 20.9 mm (0.825 inch) or less or if the diameter is 62.7 mm (2.469 inches) or less, replace outer rotor (fig. 61). If inner rotor measures 20.9 mm (0.825 inch) or less, replace inner rotor and shaft assembly (fig. 62). S...

  • Page 1680

    To 34 mm (1-11/32 inches). Replace spring that fails to meet these specifications (fig. 66). If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other reasons for oil pressure loss. Cylinder block cleaning clean cylinder block thoroughly and check all cor...

  • Page 1681

    Specifications 5.2l engine camshaft bearing diameter no. 1 . . . . . . . . . . . . . . . . . . . . 50.800 — 50.825 mm (2.000 — 2.001 in) no. 2 . . . . . . . . . . . . . . . . . . . . 50.394 — 50.419 mm (1.984 — 1.985 in) no. 3 . . . . . . . . . . . . . . . . . . . . 50.013 — 50.038 mm (1.969 — 1.970...

  • Page 1682

    Oil pressure switch actuating pressure (min.) . . . . . . . 34.5 — 48.3 kpa (5 — 7 psi) *caution: if pressure is zero at curb idle, do not run engine at 3,000 rpm. Oil filter bypass valve setting . . . . . . . . . . . . . 62 — 103 kpa (9 — 15 psi) pistons clearance at top of skirt . . . . 0.0127 — 0...

  • Page 1683

    Valve springs free length (approx.) . . . . . . . 49.962 mm (1.967 in) spring tension (valve closed) . @ 41.66 mm = 378 n (@ 1.64 in = 85 lbs) spring tension (valve open) . @ 30.89 mm = 890 n (@ 1.212 in = 200 lbs) number of coils . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 installed heigh...

  • Page 1684

    Torque 9 - 86 5.2l engine zg specifications (continued).

  • Page 1685

    Special tools 5.9l engine oil pressure gauge c-3292 engine support fixture c-3487–a valve spring compressor md-998772–a adapter 6633 adapter 6716a valve guide sleeve c-3973 dial indicator c-3339 puller c-3688 zg 5.2l engine 9 - 87.

  • Page 1686

    Front oil seal installer 6635 cam bearing remover/installer c-3132–a camshaft holder c-3509 distributor bushing puller c-3052 distributor bushing driver/burnisherc-3053 piston ring compressor c-385 crankshaft main bearing remover c-3059 cylinder bore gauge c-119 9 - 88 5.2l engine zg special tools (...

  • Page 1687

    5.9l engine index page page general information oil pump pressure . . . . . . . . . . . . . . . . . . . 89 piston and connecting rod assembly . 89 description and operation engine components . . . . . . . . . . . . . . . . . 92 engine description . . . . . . . . . . . . . . . . . . 89 lubrication sy...

  • Page 1688

    Engine type . . . . . . . . . . . . . . . . . . . . . 90° v-8 ohv firing order . . . . . . . . . . . . . . . . . 1–8–4–3–6–5–7–2 lubrication . . . Pressure feed – full flow filtration engine oil capacity . . . . . . . 4.7l (5.0 qts.) w/filter cooling system . Liquid cooled – forced circulation cooli...

  • Page 1689

    Fig. 3 oil lubrication system zg 5.9l engine 9 - 91 description and operation (continued).

  • Page 1690

    Engine components cylinder heads the alloy cast iron cylinder heads (fig. 4) are held in place by 10 bolts. The spark plugs are located in the peak of the wedge between the valves. The 5.9l cylinder head is identified by the foundry mark cf. Pistons the pistons are elliptically turned so that the di...

  • Page 1691

    Imaginary center line through both camshaft and crankshaft bores. (7) place timing chain around both sprockets. (8) turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in cam- shaft sprocket. (9) lift sprockets and chain (keep sprockets tight against the chain in ...

  • Page 1692

    (0.0029-0.0038 inch) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 inch) side clearance. (e) pistons with insufficient or excessive side clearance should be replaced. Fitting connecting rod bearings fit all rods on a bank until co...

  • Page 1693

    Crankshaft service a crankshaft which has undersize journals will be stamped with 1/4 inch letters on the milled flat on the no.3 crankshaft counterweight (fig. 13). For example: r2 stamped on the no.3 crank- shaft counterweight indicates that the no.2 rod jour- nal is 0.025 mm (0.001 in) undersize....

  • Page 1694

    (a) right side—install the sill bracket assem- bly onto the sill assembly (fig. 14). Install and tighten the bolts to 65 n·m (48 ft. Lbs.) torque. (b) left side—install the sill bracket assem- bly onto the sill assembly (fig. 15). Install and tighten the 2 top bolts to 65 n·m (48 ft. Lbs.) torque. I...

  • Page 1695

    Engine assembly removal (1) scribe hood hinge outlines on hood and remove the hood. (2) remove the battery. (3) drain cooling system. (4) remove the air cleaner and tube. (5) set fan shroud aside. (6) remove radiator and heater hoses. Remove the radiator (refer to group 7, cooling system). (7) remov...

  • Page 1696

    (3) inspect cover for distortion and straighten, if necessary. (4) check the gasket for use in head cover instal- lation. If damaged, use a new gasket. (5) position the cylinder head cover onto the gas- ket. Tighten the bolts to 11 n·m (95 in. Lbs.) torque. (6) install closed crankcase ventilation s...

  • Page 1697

    (7) perform the fuel system pressure release pro- cedure (refer to group 14, fuel system). Disconnect the fuel lines. (8) disconnect accelerator linkage and if so equipped, the speed control and transmission kick- down cables. (9) remove the return spring. (10) remove distributor cap and wires. (11)...

  • Page 1698

    (4) coat valve stems with lubrication oil and insert them in cylinder head. (5) if valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. (6) install new seals on all valve guides. Install valve springs and valve retainers. (7) compress valve springs with...

  • Page 1699

    (4) install the crankshaft pulley. Tighten the pul- ley bolts to 23 n·m (200 in. Lbs.) torque. (5) install the serpentine belt (refer to group 7, cooling system). (6) install the cooling system fan. Tighten the bolts to 23 n·m (17 ft. Lbs.) torque. (7) position the fan shroud and install the bolts. ...

  • Page 1700

    (10) install water pump and housing assembly using new gaskets (refer to group 7, cooling sys- tem). Tighten bolts to 41 n·m (30 ft. Lbs.) torque. (11) install power steering pump (refer to group 19, steering). (12) install the serpentine belt (refer to group 7, cooling system). (13) install the coo...

  • Page 1701

    Being careful not to damage cam bearings with the cam lobes. Installation (1) lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block. Note: whenever an engine has been rebuilt, a new camshaft and/or new tappet...

  • Page 1702

    Tool c-3132-a) at back of each bearing shell. Drive out bearing shells (fig. 31). Installation (1) install new camshaft bearings with camshaft bearing remover/installer tool c-3132-a by sliding the new camshaft bearing shell over proper adapter. (2) position rear bearing in the tool. Install horse- ...

  • Page 1703

    (2) drive bushing and tool into position, using a hammer (fig. 34). (3) as the burnisher is pulled through the bushing, the bushing is expanded tight in the block and bur- nished to correct size (fig. 35). Do not ream this bushing. Caution: this procedure must be followed when installing a new bushi...

  • Page 1704

    (5) position the oil pan over the dowels and onto the gasket. If equipped with an oil level sensor, take care not to damage the sensor. (6) install the oil pan bolts. Tighten the bolts to 24 n·m (215 in. Lbs.) torque. (7) remove the dowels. Install the remaining oil pan bolts. Tighten these bolts to...

  • Page 1705

    (3) immerse the piston head and rings in clean engine oil. Slide piston ring compressor tool c-385 over the piston and tighten with the special wrench (part of tool c-385). Be sure position of rings does not change during this operation. (4) install connecting rod bolt protectors on rod bolts, the l...

  • Page 1706

    (2) hold the oil pump base flush against mating surface on no.5 main bearing cap. Finger tighten pump attaching bolts. Tighten attaching bolts to 41 n·m (30 ft. Lbs.) torque. (3) install the oil pan. Front crankshaft oil seal the oil seal can be replaced without removing the timing chain cover provi...

  • Page 1707

    (10) install the vibration damper. (11) connect the negative cable to the battery. Crankshaft rear oil seals the service seal is a 2 piece, viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a...

  • Page 1708

    (4) install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. (5) apply 5 mm (0.20 in) drop of loctite 518, or equivalent, on each side of the rear main bearing cap (fig. 45). Do not over apply sealant or allow the sealant to contact...

  • Page 1709

    (2) using proper plug drive, drive cup plug into hole. The sharp edge of the plug should be at least 0.50 mm (0.020 in.) inside the lead-in chamfer. (3) it is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately. Disassembly ...

  • Page 1710

    Size stems if dial indicator reading is excessive or if the stems are scuffed or scored. (4) service valves with oversize stems are avail- able (fig. 52). (5) slowly turn reamer by hand and clean guide thoroughly before installing new valve. Ream the valve guides from standard to 0.381 mm (0.015 inc...

  • Page 1711

    Pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is trans- ferred to the top edge of valve face, lower valve seat with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat with a 60° stone. (4) when seat is proper...

  • Page 1712

    Assemble (1) install the piston and connecting rod assembly. (2) install the oil pan. (3) install the cylinder head. (4) install the engine into the vehicle. Cleaning and inspection cylinder heads cleaning clean all surfaces of cylinder block and cylinder heads. Clean cylinder block front and rear g...

  • Page 1713

    Can be inserted between cover and straightedge, pump assembly should be replaced. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 20.9 mm (0.825 inch) or less or if the diameter is 62.7 mm (2.469 inches) or less, replace outer rotor (fig. 61). If inner rotor measures...

  • Page 1714

    If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other reasons for oil pressure loss. Cylinder block cleaning clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. Inspection examine block for cracks or fractures. The c...

  • Page 1715

    Specifications 5.9l engine camshaft bearing diameter no. 1 . . . . . 50.800 — 50.825 mm (2.000 — 2.001 in) no. 2 . . . . . 50.394 — 50.419 mm (1.984 — 1.985 in) no. 3 . . . . . 50.013 — 50.038 mm (1.969 — 1.970 in) no. 4 . . . . . 49.606 — 49.632 mm (1.953 — 1.954 in) no. 5 . . . . . . . . . . . . ....

  • Page 1716

    Oil pump clearance over rotors (max.) . 0.1016 mm (0.004 in) cover out-of-flat (max.) . . . . 0.0381 mm (0.0015 in) inner rotor thickness (min.) . 20.955 mm (0.825 in) outer rotor clearance (max.) . . . . . . . . . . . 0.3556 mm (0.014 in) diameter (min.) . . . . . . . . . . 62.7126 mm (2.469 in) th...

  • Page 1717

    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 crankshaf...

  • Page 1718

    Description torque transmission support bracket bolts . . . . . . . . . . . . . . . . . . . 102 n·m (75 ft. Lbs.) transmission support spacer to insulator mounting plate – (4wd) nuts . . . . . . . . . . . . . . . . . . 204 n·m (150 ft. Lbs.) vibration damper bolt . . . . . . . . . . . . . . . . . . ...

  • Page 1719

    Dial indicator c-3339 puller c-3688 front oil seal installer 6635 cam bearing remover/installer c-3132–a camshaft holder c-3509 distributor bushing puller c-3052 distributor bushing driver/burnisherc-3053 piston ring compressor c-385 zg 5.9l engine 9 - 121 special tools (continued).

  • Page 1720

    Crankshaft main bearing remover c-3059 cylinder bore gauge c-119 9 - 122 5.9l engine zg special tools (continued).

  • Page 1721: Engine

    Engine contents page page general information engine identification . . . . . . . . . . . . . . . . . 1 hydraulic tappets . . . . . . . . . . . . . . . . . . . 2 description and operation lubrication system . . . . . . . . . . . . . . . . . . . 2 diagnosis and testing service diagnosis—diesel— perfo...

  • Page 1722

    Hydraulic tappets before disassembling any part of the engine to cor- rect tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending unit. The pressure should be between 4 bars (50 psi) at 3000 rpm. Check the oil level after the engi...

  • Page 1723

    Diagnosis and testing service diagnosis—diesel—performance zg engine 9 - 3.

  • Page 1724

    9 - 4 engine zg diagnosis and testing (continued).

  • Page 1725

    Zg engine 9 - 5 diagnosis and testing (continued).

  • Page 1726

    9 - 6 engine zg diagnosis and testing (continued).

  • Page 1727

    Zg engine 9 - 7 diagnosis and testing (continued).

  • Page 1728

    9 - 8 engine zg diagnosis and testing (continued).

  • Page 1729

    Service diagnosis—diesel—mechanical. Zg engine 9 - 9 diagnosis and testing (continued).

  • Page 1730

    9 - 10 engine zg diagnosis and testing (continued).

  • Page 1731

    Zg engine 9 - 11 diagnosis and testing (continued).

  • Page 1732

    Tappet noise (1) to determine source of tappet noise, operate engine at idle with cylinder head covers removed. (2) feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. Note: worn valve g...

  • Page 1733

    Valve seat refacing (1) install a pilot of the correct size in the valve guide bore. Reface the valve seat to the specified angle with a good dressing stone. Remove only enough metal to provide a smooth finish. (2) use tapered stones to obtain the specified seat width when required. Valve stand down...

  • Page 1734

    Valve stem-to-guide clearance measurement (1) measure and record internal diameter of valve guides. Valve guide internal diameter is 8.0 to 8.015 mm (.3149 to .3155 ins.). (2) measure valve stems and record diameters. Intake valve stem diameter 7.94 to 7.96 mm (.3125 to .3133 in). Exhaust valve stem...

  • Page 1735

    Engine mount—rear a resilient rubber cushion supports the transmis- sion at the rear between the transmission extension housing and the rear support crossmember or skid plate. Removal (1) disconnect negative cable from battery. (2) raise the vehicle and support the transmission. (3) remove the nuts ...

  • Page 1736

    (11) tip radiator, a/c condenser, and fan shroud assembly away from engine. (12) remove fan and set fan inside fan shroud. (13) remove fan, fan shroud, radiator, and a/c condenser as an assembly. (14) disconnect the heater hoses and coolant recovery bottle hose (fig. 10). (15) remove fuel lines, fue...

  • Page 1737

    (13) lower the vehicle. (14) connect all the vacuum hoses and wire con- nectors. (15) if equipped with power steering: (a) remove the protective caps (b) connect the pressure hoses to the steering gear. Tighten the nut to 28 n·m (21 ft. Lbs.). (c) connect return line from reservoir to the pump. (d) ...

  • Page 1738

    (7) lower vehicle. (8) install valve cover, tighten nuts to 19 n·m (168 in. Lbs.). (9) connect crankcase breather hose. (10) install water manifold and tighten bolts to 12 n·m (106 in. Lbs.). (11) install generator support brace. (12) connect coolant tank hose to water manifold. (13) connect the upp...

  • Page 1739

    (5) install rocker arms (refer to rocker arms in this section). (6) install cylinder head cover (refer to cylinder valve cover installation in this section). (7) start and operate engine. Warm up to normal operating temperature. Caution: to prevent damage to valve mechanism, engine must not be run a...

  • Page 1740

    Installation (1) install valve spring and retainer. (2) compress the valve spring with valve spring compressor tool and insert the valve locks. Release the spring tension and remove the tool. Tap the spring from side-to-side to ensure that the spring is seated properly on the engine cylinder head. (...

  • Page 1741

    (24) remove crankcase breather hose from rear of the valve cover (25) remove the injector sensor wire and the glow plug hot lead. (26) remove fuel lines, fuel filter, refer to group 14, fuel systems. (27) remove injector fuel lines from injectors to pump. (28) remove fuel injectors with tool vm-1012...

  • Page 1742

    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 special tool...

  • Page 1743

    Position, completely covered. Then, lubricate and install the eight small bolts, also finger tight. (6) hand tighten oil feed line for rocker arm assemblies (7) install the intake and exhaust manifolds with new gaskets, partially tightening the nuts to a max- imum of 5 n·m (44 in. Lbs.). This will a...

  • Page 1744

    (21) install transmission crossmember bolts (22) install exhaust down pipe to turbocharger, tighten bolts to 22 n·m (16 ft. Lbs.). (23) install exhaust down pipe heat shield. (24) install exhaust heat shield, tighten bolts to 11 n·m (8 ft. Lbs.). (25) install egr valve to intake manifold, tighten bo...

  • Page 1745

    Timing case cover oil seal removal (1) disconnect the battery cable. (2) remove vibration damper (refer to vibration damper removal in this section). (3) pry out seal. Installation remove the oil seal ring. The seating diameter must be 68.000 - 68.030 mm. (1) install new seal using special tool vm-1...

  • Page 1746

    (3) install power steering pulley, tighten to 130 n·m (96 ft. Lbs.). (4) connect oil drain to cover. (5) install automatic belt tensioner. (6) install idler pulley bracket, tighten bolts to 40 n·m (29 ft. Lbs.). (7) install idler pulley, bolt has left hand thread, tighten to 65 n·m (48 ft. Lbs.). (8...

  • Page 1747

    Installation (1) coat the camshaft journals with clean engine oil and carefully install the camshaft complete with thrust plate and gear. Tighten retaining bolts to 24 n·m ( 18 ft. Lbs.) torque. Be sure to align the timing marks as shown (fig. 33). (2) install hydraulic tappets and retaining yokes. ...

  • Page 1748

    Installation (1) remove all gasket material from cylinder block. Be careful not gouge or scratch aluminum pan seal- ing surface. (2) install oil pan. Apply a continuous 3 mm bead of silicone sealer to oil pan, install within 10 min- utes. (3) install inside oil pan bolts and torque bolts to 11 n·m (...

  • Page 1749

    Installation (1) to install the vacuum pump, align the outer part of the gear with the inner part using a screw- driver or similar tool, align with timing marks on gear set and install. (2) install bolts and tighten to 20 n·m (15 ft. Lbs.). (3) install front cover. Oil pump pressure relief valve rem...

  • Page 1750

    (4) remove oil cooler adapter bolt. (5) remove oil cooler (fig. 41). Installation (1) install oil cooler with new gasket, tighten oil cooler adapter bolt to 60 n·m (44 ft. Lbs.). (2) install oil filter base with new o-ring and tighten bolt to 46.6 n·m (34 ft. Lbs.). (3) install oil filter adapter to...

  • Page 1751

    Piston ring fitting (1) wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore. Check gap with feeler gauge. Top com- pression ring gap .25 ...

  • Page 1752

    (2) top compression ring is tapered and chromium plated. The second ring is of the scraper type and must be installed with scraping edge facing bottom of the piston. The third is an oil control ring. Ring gaps must be positioned, before inserting piston into the liners, as follows (fig. 48). (3) top...

  • Page 1753

    (4) face chamber recess side of piston towards camshaft. (5) install connecting rod bolt protectors on rod bolts. (6) rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. (7) ta...

  • Page 1754

    (2) measure the liner recess relative to block deck with a dial indicator mounted on a special tool vm-1010 a. All the measurements must be taken on camshaft side . Zero dial gauge on block deck. (3) move dial gauge to cylinder liner record read- ing on dial gauge. (4) remove liner and special tool....

  • Page 1755

    Crankshaft main bearings removal (1) disconnect battery cable. (2) remove engine from vehicle, refer to engine removal in this section. (3) install engine to engine stand. (4) remove accessary drive system. (5) remove cylinder head cover, refer to cylinder head cover removal in this section. (6) rem...

  • Page 1756

    (17) install special tool vm-1004 onto crankshaft over gear (fig. 55). (18) remove main bearing oil feed and carrier locators from block. (19) remove flywheel and adaptor plate from engine block. (20) remove thrust bearings from rear main bear- ing carrier. (21) slide crankshaft and bearing carriers...

  • Page 1757

    (7) slide special tool (vm-1002) over the crank- shaft gear and, insert the crankshaft and carrier assembly into the crankcase in the same manner used for removal. (8) align the holes in the lower carriers, with the center of the crankcase webs (fig. 58). (9) secure each carrier assembly to the cran...

  • Page 1758

    (32) before installing oil pump check pump bore depth in block (a) and pump body height (b) (fig. 60). Difference between a and b should be 0.020-0.082 mm (.0007 to 0032 in.). (33) install oil pump and tighten retaining screws to 27 n·m (20 ft.Lbs.). Check for normal backlash between pump and cranks...

  • Page 1759

    Rocker arms and push rods cleaning clean all the components (fig. 62) with cleaning solvent. Use compressed air to blow out the oil passages in the rocker arms and push rods. Inspection inspect the pivot surface area of each rocker arm. Replace any that are scuffed, pitted, cracked or excessively wo...

  • Page 1760

    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 having coated threads with molyguard, tighten con rod bolts to 29 n·m (21 ft. Lbs.) plus 60°. Inspection—piston pin (1) measure the diameter of piston pin in the cen- ter and both e...

  • Page 1761

    Oil pump cleaning wash all parts in a suitable solvent and inspect carefully for damage or wear. Inspection (1) before installing oil pump check pump bore depth in block (a) and pump body height (b) (fig. 67). Difference between a and b should be 0.020-0.082 mm. (2) check clearance between rotors (f...

  • Page 1762

    Specifications engine specifications 9 - 42 engine zg.

  • Page 1763

    Zg engine 9 - 43 specifications (continued).

  • Page 1764

    Torque specifications description torque automatic belt tensioner to block bolts (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 n·m automatic belt tensioner to mounting bracket bolt (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 n·m generator belt tensioner . . . ....

  • Page 1765

    Description torque rocker mounting lock nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 n·m steering pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 n·m turbocharger mounting nuts . . . . . . . . . . . . . . . . . . . . . . 32.5 n·m turbocharger oil delivery ...

  • Page 1766

    Crankshaft remover/replacer sleeve vm. 1004 torque angle gauge vm. 1005 cylinder head bolt wrench vm. 1006a cylinder head guide studs vm. 1009 cylinder liner protrusion tool vm. 1010 bosch pump timing adapter vm. 1011 9 - 46 engine zg special tools (continued).

  • Page 1767

    Injector remover/replacer socket vm. 1012 dial indicator gauge vm. 1013 flywheel locking tool vm. 1014 timing cover oil seal replacer vm. 1015 cylinder retainer vm. 1016 crankshaft and water pump pulley holder vm. 1017 zg engine 9 - 47 special tools (continued).

  • Page 1768

    Cylinder head bolt wrench m12 vm. 1018 cylinder head bolt wrench m14 vm. 1019 cylinder leakage tester adapter vm. 1021 9 - 48 engine zg special tools (continued).

  • Page 1769

    Exhaust system and intake manifold contents page page general information catalytic converter . . . . . . . . . . . . . . . . . 2 exhaust system . . . . . . . . . . . . . . . . . . . . . . 1 heat shields . . . . . . . . . . . . . . . . . . . . . . . . . 2 diagnosis and testing exhaust system diagnos...

  • Page 1770

    When replacement is required, use original equip- ment parts (or their equivalent). This will assure proper alignment and provide acceptable exhaust noise levels. Caution: avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields. Light overspr...

  • Page 1771

    Diagnosis and testing exhaust system diagnosis removal and installation exhaust pipe removal warning: if torches are used when work- ing on the exhaust system, do not allow the flame near the fuel lines. (1) raise and support the vehicle. (2) saturate the bolts and nuts with heat valve lubricant. Al...

  • Page 1772

    Catalytic converter removal warning: if torches are used when work- ing on the exhaust system, do not allow the flame near the fuel lines. (1) raise and support the vehicle. (2) saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. (3) remove exhaust clamp from the ...

  • Page 1773

    (7) while the metal is still cherry red, twist the catalytic converter back and forth to separate it from the exhaust pipe and the muffler. Installation (1) position the exhaust clamp over the exhaust pipe/catalytic converter connection (fig. 8). Tighten the nuts to 61 n·m (45 ft. Lbs.) torque. (2) ...

  • Page 1774

    (3) remove the air cleaner assembly. (4) remove the throttle cable, vehicle speed control cable (if equipped) and the transmission line pres- sure cable. (5) disconnect all electrical connectors on the intake manifold. (6) disconnect and remove the fuel system supply and return lines from the fuel r...

  • Page 1775

    (6) disconnect the accelerator linkage and, if so equipped, the speed control and transmission kick- down cables. (7) remove the return spring. (8) remove the distributor cap and wires. (9) disconnect the coil wires. (10) disconnect the heat indicator sending unit wire. (11) disconnect the heater ho...

  • Page 1776

    (fig. 13). The words manifold side should be vis- ible on the center of each flange gasket. (7) carefully lower intake manifold into position on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to posi- tion the intake manifold. After intake manifold is in pl...

  • Page 1777

    Installation caution: if the studs came out with the nuts when removing the exhaust manifold, install new studs. (1) position the exhaust manifolds on the two studs located on the cylinder head. Install conical washers and nuts on these studs (fig. 16). (2) install new bolt and washer assemblies in ...

  • Page 1778

    Specifications torque description . . . . . . . . . . . . . . . . . . . Torque adjusting strap bolts . . . . . . . . . . . . . . . . . . . 23 n·m (200 in. Lbs.) catalytic converter-to-exhaust pipe u-bolt rod clamp . . . . . . . . . . . 61 n·m (45 ft. Lbs.) exhaust pipe-to-manifold nuts . . . . . . ....

  • Page 1779

    Exhaust system and intake manifold contents page page general information exhaust system . . . . . . . . . . . . . . . . . . . . . . 1 exhaust heat shields . . . . . . . . . . . . . . . . . 1 removal and installation exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . 2 muffler and exhaus...

  • Page 1780

    Removal and installation exhaust pipe warning: if torches are used when work- ing on the exhaust system, do not allow the flame near the fuel lines. Removal (1) raise and support the vehicle. (2) saturate the bolts and nuts at turbo down pipe to exhaust pipe with heat valve lubricant. Allow 5 minute...

  • Page 1781

    Engine exhaust manifold and turbocharger removal (1) disconnect the battery negative cable. (2) remove air cleaner hoses from turbocharger. (3) remove air cleaner assembly. (4) remove charge air cooler hoses from turbo- charger and intake manifold. (5) remove all components attached to the intake ma...

  • Page 1782

    Specifications torque specifications description torque egr attaching nuts . . . . . . . . . . . . . . . . . . . . . . . 28 n·m egr tube nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 n·m egr tube flange bolts . . . . . . . . . . . . . . . . . . . . . 26 n·m exhaust manifold nuts . . ....

  • Page 1783: Frame And Bumpers

    Frame and bumpers contents page page bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 bumpers index page page removal and installation front bumper/fascia . . . . . . . . . . . . . . . . . 1 rear bumper fasc...

  • Page 1784

    Rear bumper fascia removal (1) raise and support the rear of the vehicle. (2) remove the upper scuff pad from fascia. (3) remove the lower retainers from fascia (fig. 5). (4) remove the push-in retainers located at the rear wheel well on each side. (5) remove the fascia from the bumper. Installation...

  • Page 1785

    Frame index page page general information general information . . . . . . . . . . . . . . . . . 3 removal and installation brush guard . . . . . . . . . . . . . . . . . . . . . . . . . 3 front skid plate . . . . . . . . . . . . . . . . . . . . . 4 front tow hook . . . . . . . . . . . . . . . . . . ....

  • Page 1786

    (3) push the top of the brush guard inward until it contacts the front fascia. (4) tighten the bolts to 28 n·m (20 ft. Lbs.) torque. Front skid plate removal (1) position a support under skid plate. (2) remove the bolts that attach skid plate to frame (fig. 4). (3) lower the skid plate. Installation...

  • Page 1787

    Fuel tank skid plate removal (1) remove trailer hitch. (2) position a support under the fuel tank skid plate. (3) remove nuts attaching skid plate to frame rails (fig. 6). (4) lower skid plate and remove support. Installation (1) position skid plate on a support and raise into position. (2) install ...

  • Page 1788

    Installation (1) place hitch on a lifting device. Raise, position hitch at proper location and support it. (2) loosely install nuts that attach towing tube to vehicle frame sills. (3) position plate bracket and install attaching bolts through vehicle rear crossmember. (4) tighten all attaching bolts...

  • Page 1789

    Fig. 9 vehicle dimensions—front/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 radiu...

  • Page 1790

    Fig. 10 vehicle dimensions—side 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...

  • Page 1791

    Fig. 11 vehicle dimensions—rear viewand engine compartment a. Center of upper liftgate opening to liftgate striker mount. B. & c. Center of radius upper corner to center of radius lower corner. D. Distance between outer quarter panel to tail lamp mounting panel to inner quarter panel seams. Zg frame...

  • Page 1792

    Fig. 12 frame dimensions—side 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 = ...

  • Page 1793

    Fig. 13 frame dimensions—bottom view all measurements in m bottom view bottom view point-to-point dimensions are taken with tram bar pointers set at equal lengths. Bolts and studs are measured to center. Holes are measured to closest edge. Driver side front zg frame and bumpers 13 - 11 specification...

  • Page 1794

    Torque specifications description torque front tow hook nut . . . . . . . . . 100 n·m (74 ft. Lbs.) front skid plate bolt . . . . . . . . . 54 n·m (40 ft. Lbs.) fuel tank skid plate nuts . . . . . 74 n·m (55 ft. Lbs.) fuel tank skid plate mtg studs . 108 n·m (80 ft. Lbs.) rear bumper bolt . . . . . ...

  • Page 1795: Fuel System

    Fuel system contents page page fuel delivery system . . . . . . . . . . . . . . . . . 3 fuel injection system . . . . . . . . . . . . . . . . 26 general information . . . . . . . . . . . . . . . . . . 1 general information index page page general information fuel requirements . . . . . . . . . . . ....

  • Page 1796

    Use of methanol/gasoline blends may result in starting and driveability problems and damage criti- cal fuel system components. Problems that are the result of using methanol/ gasoline blends are not the responsibility of chrysler corporation and may not be covered by the vehicle warranty. Reformulat...

  • Page 1797

    Fuel delivery system index page page description and operation fuel delivery system . . . . . . . . . . . . . . . . . 3 fuel filter/fuel pressure regulator . . 4 fuel gauge sending unit . . . . . . . . . . . . . . 4 fuel injectors—4.0l engine . . . . . . . . . . . 5 fuel injectors—5.2l/5.9l engines ...

  • Page 1798

    Fuel pump module the fuel pump module is installed in the top of the fuel tank (fig. 1) or (fig. 2). The fuel pump module contains the following components: • a combination fuel filter/fuel pressure regulator • a separate fuel pick-up filter (strainer) • an electric fuel pump • a threaded locknut to...

  • Page 1799

    Tains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly. Fuel is supplied to the filter/regulator by the elec- tric fuel pump through an opening tube at the bot- tom of filter/regulator (fig. 3). The regulator acts as a check valve to main...

  • Page 1800

    With an attached numerical tag (inj 1, inj 2 etc.). This is used to identify each fuel injector. The injectors are energized individually in a sequential order by the powertrain control module (pcm). The pcm will adjust injector pulse width by switching the ground path to each individual injector on...

  • Page 1801

    Diagnosis and testing fuel pump pressure test–4.0l engine use this test in conjunction with the fuel pump capacity test and fuel pressure leak down test found elsewhere in this group. Check valve operation: the electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into t...

  • Page 1802

    (1) remove the protective cap at the fuel rail test port. Connect the 0–414 kpa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail (fig. 8). (2) start and warm the engine and note pressure gauge reading. Fuel pressure should be 339 kpa 6 34 kpa (4...

  • Page 1803

    (4) install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. (5) connect vehicle fuel line into adapter tool 6923 (fig. 9). Be sure fuel line is fully seated into adapter tool 6923. (6) remove protective cap at test ...

  • Page 1804

    (7) pressure should not fall below 30 psi for five minutes. (8) if pressure falls below 30 psi, it must be deter- mined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. (9) again, start engine and bring to normal oper- ating temperature. (10) shut engi...

  • Page 1805

    Warning: because the fuel system is under constant fuel pressure, the pres- sure must be released before servicing any fuel system component. This does not apply to throttle body removal. (1) disconnect negative battery cable. (2) remove the fuel tank filler tube cap to release fuel tank pressure. (...

  • Page 1806

    Never attempt to repair a plastic fuel line/tube. Replace as necessary. Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to avoid heat sources. The lines/t...

  • Page 1807

    (9) prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. (10) insert the quick-connect fitting into the fuel tube or fuel system component until the built-on ...

  • Page 1808

    Plastic retainer ring type fitting this type of fitting can be identified by the use of a full-round plastic retainer ring (fig. 17) usually black in color. Caution: the interior components (o-rings, spac- ers, retainers) of this type of quick-connect fitting are not serviced separately. Do not atte...

  • Page 1809

    (4) pry up on the latch clip with a screwdriver (fig. 19). (5) slide the latch clip toward the fuel rail while lifting with the screwdriver. (6) insert special fuel line removal tool (snap-on number fih 9055- 1 or equivalent) into the fuel line (fig. 20). Use this tool to release the locking fingers...

  • Page 1810

    Fuel rail if properly installed (fig. 21). If the latch clip will not fit, this indicates the fuel line is not properly installed to the fuel rail. Recheck the fuel line connection. (11) verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). (12) connect negative battery ...

  • Page 1811

    (7) rotate filter/regulator until fuel supply tube (fitting) is pointed to 11 o’clock position. (8) install new retainer clamp (clamp snaps over top of filter/regulator and locks to flanges on pump module). (9) install fuel tank. Refer to fuel tank removal/ installation. Fuel pump module fuel tank r...

  • Page 1812

    Removal (1) remove fuel tank. Refer to fuel tank removal/ installation. (2) remove fuel pump module. Refer to fuel pump module removal/installation. (3) remove filter by prying from bottom of module with 2 screwdrivers. Filter is snapped to module. (4) clean bottom of pump module. Installation (1) s...

  • Page 1813

    (8) remove the remaining fuel rail mounting bolts. (9) gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/righ...

  • Page 1814

    (12) install air duct to throttle body. (13) connect battery cable to battery. (14) start engine and check for leaks. Fuel injector rail—4.0l engine removal warning: the fuel system is under con- stant fuel pressure even with the engine off. This pressure must be released before servicing the fuel r...

  • Page 1815

    Installation (1) apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation. (2) install injector(s) and injector clip(s) to fuel rail. (3) install fuel rail assembly. Refer to fuel injector rail installation. (4) install air duct at throttle body. (5) ...

  • Page 1816

    (12) disconnect fuel pump module electrical con- nector (pigtail harness) near front of tank (fig. 38). Harness connector is clipped to body. (13) remove two fuel tank strap nuts (fig. 37). Position both tank support straps away from tank. (14) carefully lower right side of tank while feed- ing both...

  • Page 1817

    Accelerator pedal the accelerator pedal is connected to the throttle body linkage by the throttle cable. The cable is pro- tected by a plastic sheathing and is connected to the throttle body linkage by a ball socket. It is connected to the accelerator pedal arm by a plastic retainer (clip) (fig. 40)...

  • Page 1818

    Prevent cable housing breakage, press on the tab only enough to release the cable from the bracket. Lift the cable housing straight up from bracket while pressing on release tab. Remove throt- tle cable from vehicle. Installation (1) 4.0l engine: slide throttle cable through hole in throttle body br...

  • Page 1819

    Torque chart description torque accelerator pedal bracket mounting nuts . . . . . . . . . . . 8.5 n·m (75 in. Lbs.) fuel pump module locknut . . . . 34 n·m (25 ft. Lbs.) fuel rail mounting bolts— 4.0l engine . . . . . . . . . . . . . 11 n·m (100 in. Lbs.) fuel rail mounting bolts— 5.2l/5.9l engines ...

  • Page 1820

    Fuel injection system index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . 27 modes of operation . . . . . . . . . . . . . . . . . 27 description and operation oxygen sensor (o2s)—pcm input . . . . . . 34 air conditioning (a/c) clutch relay— pcm output . . ....

  • Page 1821

    Transmission governor pressure sensor—pcm input . . . . . . . . . . . . . . . . . 36 transmission park/neutral switch— pcm input . . . . . . . . . . . . . . . . . . . . . . . . . 36 transmission relay—pcm output . . . . . 41 transmission temperature sensor— pcm input . . . . . . . . . . . . . . . . ...

  • Page 1822

    Is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: • ignition switch on • engine start-up (crank) • engine warm-up • idle • cruise • acceleration • deceleration • wide open throttle (wot) • ignition s...

  • Page 1823

    • voltage is applied to the fuel injectors with the asd relay via the pcm. The pcm will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. • the pcm adjusts engine idle speed through the idle air control (iac) motor and ...

  • Page 1824

    Supply a ground to the injectors. If a hard decelera- tion does not exist, the pcm will determine the proper injector pulse width and continue injection. Based on the above inputs, the pcm will adjust engine idle speed through the idle air control (iac) motor. The pcm adjusts ignition timing by turn...

  • Page 1825

    • output shaft speed sensor • overdrive/override switch • oxygen sensors • park/neutral switch (auto. Trans. Only) • power ground • sensor return • signal ground • speed control multiplexed single wire input • throttle position sensor • transmission governor pressure sensor • transmission temperatur...

  • Page 1826

    Reduced flow through injector caused by the lowered voltage. Brake switch—pcm input when the brake light switch is activated, the pow- ertrain control module (pcm) receives an input indi- cating that the brakes are being applied. After receiving this input, the pcm maintains idle speed to a schedule...

  • Page 1827

    Tion event is to be required. The output from this sensor, in conjunction with the camshaft position sen- sor signal, is used to differentiate between fuel injec- tion and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor is bolted to the tra...

  • Page 1828

    Generator output—pcm input provides a charging system voltage input to the powertrain control module (pcm). It is sensed at the battery input to the pcm. Oxygen sensor (o2s)—pcm input two heated o2s sensors are used. The sensors pro- duce voltages from 0 to 1 volt, depending upon the oxygen content ...

  • Page 1829

    Leak detection pump (switch) sense—pcm input provides an input to the pcm that the leak detec- tion pump (ldp) has been activated. Refer to group 25, emission control system for ldp information. Manifold absolute pressure (map) sensor—5.2l/5.9l engines—pcm input the map sensor reacts to absolute pre...

  • Page 1830

    This input is used with 4–speed electronic transmis- sions only. Overdrive/override switch-pcm input on vehicles equipped with an automatic transmis- sion and overdrive, the powertrain control module (pcm) regulates the 3-4 overdrive up-shift and down- shift through the overdrive solenoid. This sole...

  • Page 1831

    The pcm supplies approximately 5 volts to the tps. The tps output voltage (input signal to the pcm) represents the throttle blade position. The pcm receives an input signal voltage from the tps. This will vary in an approximate range of from .25 volts at minimum throttle opening (idle), to 4.8 volts...

  • Page 1832

    Clutch. This is based on changes in engine operating conditions. If, during a/c operation, the pcm senses abnormally low idle speeds it will de-energize the relay. This prevents a/c clutch engagement. The relay will remain de-energized until the idle speed increases. The pcm will also de-energize th...

  • Page 1833

    Fuel injectors—4.0l engine—pcm output six individual fuel injectors are used with the 4.0l 6-cylinder engine. The injectors are attached to the fuel rail (fig. 16). The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder ...

  • Page 1834

    Ertrain control module (pcm) adjusts engine idle speed by moving the iac motor pintle in and out of the air control passage. The iac motor is positioned when the ignition key is turned to the on position. A (factory adjusted) set screw is used to mechani- cally limit the position of the throttle bod...

  • Page 1835

    This pcm output. Refer to group 25, emission con- trol system for additional information. Malfunction indicator (check engine) lamp—pcm output the malfunction indicator lamp illuminates each time the ignition key is turned on. It will stay on for approximately three seconds as a bulb test. The lamp ...

  • Page 1836

    Tions. A throttle valve (plate) is used to supply air for above idle conditions. The throttle position sensor (tps), idle air control (iac) motor and manifold absolute pressure sensor (map) are attached to the throttle body. The acceler- ator pedal cable, speed control cable and transmis- sion contr...

  • Page 1837

    Diagnostic time. A thorough visual inspection will include the following checks: (1) verify that the three 32–way electrical connec- tors are fully inserted into the connector of the pow- ertrain control module (pcm) (fig. 23). (2) inspect the battery cable connections. Be sure that they are clean a...

  • Page 1838

    Nections (if equipped). Check their connections to the throttle arm of throttle body for any binding or restrictions. (12) if equipped with vacuum brake booster, verify that vacuum booster hose is firmly connected to fit- ting on intake manifold. Also check connection to brake vacuum booster. (13) i...

  • Page 1839

    Nected to the sensors. Inspect sensors and connectors for damage (fig. 31) or (fig. 32). (22) inspect for pinched or leaking fuel tubes. Inspect for pinched, cracked or leaking fuel hoses. (23) inspect for exhaust system restrictions such as pinched exhaust pipes, collapsed muffler or plugged cataly...

  • Page 1840

    Visual inspection—4.0l engine a visual inspection for loose, disconnected or incor- rectly routed wires and hoses should be made. This should be done before attempting to diagnose or ser- vice the fuel injection system. A visual check will help spot these faults and save unnecessary test and diagnos...

  • Page 1841

    (8) verify crankcase ventilation (ccv) operation. Refer to group 25, emission control system for addi- tional information. (9) inspect fuel tube quick-connect fitting-to-fuel rail connections. (10) verify that hose connections to all ports of vacuum fittings on intake manifold are tight and not leak...

  • Page 1842

    (18) verify harness connectors are firmly con- nected to idle air control (iac) motor and throttle position sensor (tps) (fig. 39). (19) verify that wire harness connector is firmly connected to the engine coolant temperature sensor (fig. 41). (20) raise and support the vehicle. (21) verify that bot...

  • Page 1843

    (29) verify that battery cable and solenoid feed wire connections to the starter solenoid are tight and clean. Inspect for chaffed wires or wires rubbing up against other components. Asd and fuel pump relays the following description of operation and tests apply only to the automatic shutdown (asd) ...

  • Page 1844

    Priate powertrain diagnostics procedures manual. To test the map sensor only, refer to the following: (1) inspect the rubber l-shaped fitting from the map sensor to the throttle body (fig. 48). Repair as necessary. Caution: when testing the map sensor, be sure that the harness wires are not damaged ...

  • Page 1845

    (3) test powertrain control module (pcm) cavity a-27 for the same voltage described above to verify the wire harness condition. Repair as necessary. (4) test map sensor supply voltage at sensor con- nector between terminals a and c (fig. 49) with the ignition on. The voltage should be approximately ...

  • Page 1846

    Each o2s heating element can be tested with an ohmmeter as follows: disconnect the o2s sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 4.5 6 .5 ohms and 7 ohms. Replace the sen- sor if the ohmmeter displays an in...

  • Page 1847

    (2) test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. The resis- tance (as measured across the sensor terminals) should be as shown in the previous coolant temper- ature sensor/intake air temperature sensor resis- tance chart. Replace the sensor if it is not with...

  • Page 1848

    Tester and appropriate powertrain diagnostics proce- dures manual. To test the sensor only, refer to the following: (1) disconnect the wire harness connector from the intake manifold air temperature sensor (fig. 58). (2) test the resistance of the sensor with an input impedance (digital) volt-ohmmet...

  • Page 1849

    Throttle body for conditions that may cause idle prob- lems. 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 ...

  • Page 1850

    Removal (1) remove pdc cover. (2) remove relay from pdc. (3) check condition of relay terminals and pdc connector terminals for damage or corrosion. Repair if necessary before installing relay. (4) check for pin height (pin height should be the same for all terminals within the pdc connector). Repai...

  • Page 1851

    Throttle body—4.0l engine a (factory adjusted) set screw is used to mechani- cally limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the powertrain control module (pcm). Removal (1) remov...

  • Page 1852

    (1) install the tps and two retaining bolts. (2) tighten bolts to 7 n·m (60 in. Lbs.) torque. (3) manually operate the throttle control lever by hand to check for any binding of the tps. (4) connect tps electrical connector to tps. (5) install air duct at throttle body. Throttle position sensor (tps...

  • Page 1853

    Installation (1) install iac motor to throttle body. (2) install and tighten two mounting bolts (screws) to 7 n·m (60 in. Lbs.) torque. (3) install electrical connector. (4) install air duct at throttle body. Idle air control (iac) motor—4.0l engine the iac motor is located on the side of the thrott...

  • Page 1854

    Manifold absolute pressure (map) sensor—4.0l engine the map sensor is mounted to the side of the throttle body (fig. 75). An l-shaped rubber fitting is used to connect the map sensor to throttle body (fig. 76). Removal (1) remove air cleaner intake tube at throttle body. (2) remove two map sensor mo...

  • Page 1855

    Installation (1) check the pins in the three 32–way electrical connectors for damage. Repair as necessary. (2) install pcm. Tighten three mounting bolts to 1 n·m (9 in. Lbs.) torque. (3) install three 32–way connectors. (4) install cover over electrical connectors. Cover snaps onto pcm. (5) install ...

  • Page 1856

    (4) remove o2s sensor. Snap-on oxygen sensor wrench (number ya 8875) may be used for removal and installation. Installation threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. Do not add any additional anti-seize compound to threads of a new oxygen sensor. (1...

  • Page 1857

    (3) from under vehicle, remove three housing nuts (fig. 83). (4) release the air cleaner housing from the ambi- ent air duct and remove housing from vehicle. Installation (1) position air cleaner housing to body and ambi- ent air duct (fig. 83). (2) install three nuts and tighten to 10 n·m (93 in. L...

  • Page 1858

    Engine coolant temperature sensor—5.2l/ 5.9l engines removal warning: hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before remov- ing the coolant temperature sensor. Refer to group 7, cooling. (1) partially drain cooling system. Refer to group 7, coo...

  • Page 1859

    Intake manifold air temperature sensor— 4.0l engine the intake manifold air temperature sensor is installed into the intake manifold plenum near the throttle body (fig. 90). Removal (1) disconnect the electrical connector from the sensor. (2) remove the sensor from the intake manifold. Installation ...

  • Page 1860

    (2) disconnect the electrical connector from the sensor. (3) remove the sensor mounting bolt (fig. 93). (4) remove the sensor (pull straight out) from the speedometer pinion gear adapter (fig. 93). Do not remove the gear adapter from the transmission. Installation (1) clean the inside of speedometer...

  • Page 1861

    Special tools fuel system spanner wrench—6856 fitting, air metering—6714 adapters, fuel pressure test—6541,6539, 6631 or 6923 pump, im240 evap service pressure—6917 o2s (oxygen sensor) remover/installer—c-4907 test kit, fuel pressure—5069 test kit, fuel pressure—c-4799-b fuel line removal tool—6782 ...

  • Page 1863

    Fuel system—2.5l diesel engine contents page page fuel delivery system—2.5l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 fuel injection system—2.5l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 general information . . . . . . . . . . . . . ...

  • Page 1864

    A fuel return system. A separate fuel return system is used. This will route excess fuel: from the fuel injectors; through individual injector drain tubes; through the fuel injection pump overflow valve; and back to the fuel tank through a separate fuel line. The fuel tank assembly consists of: the ...

  • Page 1865

    Fuel delivery system—2.5l diesel engine index page page description and operation fuel drain tubes . . . . . . . . . . . . . . . . . . . . . 7 fuel filter/water separator . . . . . . . . . . 4 fuel gauge sending unit . . . . . . . . . . . . . . 4 fuel heater relay . . . . . . . . . . . . . . . . . ....

  • Page 1866

    Fuel tank the fuel tank and tank mounting used with the diesel powered engine is the same as used with gas- oline powered models, although the fuel tank module is different. The fuel tank contains the fuel tank module and two rollover valves. Two fuel lines are routed to the fuel tank module. One li...

  • Page 1867

    The fuel shutdown (shut-off) solenoid is used to electrically shut off the diesel fuel supply to the high- pressure fuel injection pump. The solenoid is mounted to the rear of the injection pump (fig. 4). The solenoid controls starting and stopping of the engine regardless of the position of the acc...

  • Page 1868

    Monitors outputs from the engine speed sensor (fly- wheel position in degrees), and the fuel injector sen- sor (mechanical movement within the #1 cylinder fuel injector). Outputs from the accelerator pedal position sensor, engine speed sensor (engine rpm) and engine coolant temperature sensor are al...

  • Page 1869

    The combustion chamber is stopped. Exhaust gases are prevented from entering the injector nozzle by the needle valve. A copper washer (gasket) is used at the base of each injector (fig. 7) to prevent combustion gases from escaping. Fuel injector firing sequence is 1–3–4–2. Fuel tubes/lines/hoses and...

  • Page 1870

    Line as the overflow valve, which allows a variable quantity to return to the fuel tank. The overflow valve is calibrated to open at a preset pressure. Excess fuel not required by the pump to maintain the minimum pump cavity pressure is then returned through the overflow valve and on to the fuel tan...

  • Page 1871

    Wastegate (turbocharger) refer to group 11, exhaust system and intake manifold for information. Diagnosis and testing general information this section of the group will cover a general diag- nosis of diesel engine fuel system components. Diagnostic trouble codes: refer to on-board diagnostics in gro...

  • Page 1872

    (7) be sure that the electrical connections at the glow plug relay are tight and not corroded. The glow plug relay is located in the engine compartment on the left–inner fender (fig. 15). (8) inspect the starter motor and starter solenoid connections for tightness and corrosion. (9) verify that the ...

  • Page 1873

    (14) verify turbocharger wastegate operation. Refer to group 11, exhaust system and intake man- ifold group for information. (15) verify that the harness connector is firmly connected to the engine coolant temperature sensor. The sensor is located on the side of cylinder head near the rear of fuel i...

  • Page 1874

    (23) verify there is a good connection at the engine speed sensor. Refer to the fuel injection system in this section for location of the engine speed sensor location. (24) verify there is a good connection at the mass air flow sensor, which is a part of the air intake assembly. Air in fuel system a...

  • Page 1875

    Fuel injector sensor test the fuel injector sensor is used only on the fuel injector for the number–1 cylinder (fig. 24). It is not used on the injectors for cylinders number 2, 3, or 4. To test the sensor, unplug the sensor connector (fig. 24) from the engine wiring harness. Check resistance across...

  • Page 1876

    Start the engine. Move the cardboard over the high–pressure fuel lines and check for fuel spray onto the cardboard (fig. 25). If a high–pressure line con- nection is leaking, bleed the system and tighten the connection. Refer to the air bleed procedure in this group for procedures. Replace damaged, ...

  • Page 1877

    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 cranki...

  • Page 1878

    Installation (1) place accelerator pedal assembly over studs protruding from floor pan. Tighten mounting nuts to 5 n·m (46 in. Lbs.) torque. (2) connect electrical connector. (3) before starting the engine, operate the acceler- ator pedal to check for any binding. Air cleaner element removal (1) rem...

  • Page 1879

    (4) hold the drain open until clean fuel exits the drain. (5) after draining, close drain valve. (6) remove rubber drain hose. (7) dispose of mixture in drain pan according to applicable local or federal regulations. Fuel filter removal (1) drain all fuel and/or water from fuel filter/wa- ter separa...

  • Page 1880

    Removal (1) remove fuel tank. Refer to fuel tank removal/ installation. (2) remove fuel pump module. Refer to fuel pump module removal/installation (3) remove electrical wire connector at sending unit terminals. (4) press on release tab (fig. 33) to remove send- ing unit from pump module. Fuel injec...

  • Page 1881

    (d) remove rocker arm assembly. (e) remove valve spring 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 valve set on top of piston. Install a dial indicator to the top of the valve stem. (g) rotate engine back a...

  • Page 1882

    (3) remove the gear removing bolt (drive bolt) from gear puller. 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) place the key way on the pump shaft to the 11 o’clock position as viewed from the front o...

  • Page 1883

    (d) recheck the dial indicator after tightening the pump mounting nuts. Gauge should still be reading 0.60 mm. Loosen pump mounting nuts and readjust if necessary. (15) remove dial indicator and adapter tools. (16) install access plug and washer to rear of injection pump. (17) install plug at timing...

  • Page 1884

    (6) remove and discard the copper washer (seal) at bottom of injector (fig. 42). Installation (1) clean the injector threads in cylinder head. (2) install new copper washer (seal) to injector. (3) install injector to engine. Tighten to 70 n·m (52 ft. Lbs.) torque. (4) install high–pressure fuel line...

  • Page 1885

    (3) feed filler vent line thru frame rail. Careful not to cross lines. (4) tighten strap bolts to 54 n·m (40 ft. Lbs.) torque. Remove transmission jack. Caution: ensure straps are not twisted or bent before or after tightening strap nuts. (5) connect module electrical connector. Place retainer in lo...

  • Page 1886

    (7) lower vehicle on hoist. (8) connect negative cable from battery. (9) fill fuel tank. Check for leaks. (10) install fuel filler cap. High-pressure lines all high–pressure fuel lines are of the same length and inside diameter. Correct high–pressure fuel line usage and installation is critical to s...

  • Page 1887

    Idle speed 900 rpm 625 rpm with engine at normal operat- ing temperature. Fuel injector firing sequence 1–3–4–2 fuel system pressure peak injection pressure/fuel injection pump operating pressure: 40,000–45,000 kpa (5801– 6526 psi). Opening pressure of fuel injector: 15,000–15,800 kpa (2175–2291 psi...

  • Page 1888

    Fuel injection system—2.5l diesel engine index page page general information introduction . . . . . . . . . . . . . . . . . . . . . . . 26 description and operation air conditioning (a/c) controls—msa inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 air conditioning relay—msa outp...

  • Page 1889

    Usually indicates a problem has been detected some- where within the fuel system. The drbiii scan tool is the best method for communicating with the msa and pcm to diagnose faults within the system. Description and operation powertrain control module (pcm) the msa controller is mounted under the lef...

  • Page 1890

    • electric vacuum modulator (evm) • glow plug relay • tachometer the pcm sends and recieves signals to and from the msa controller. Pcm inputs are: • power gound • 5 volts supply • vehicle speed sensor • water-in-fuel sensor • coolant temperature sensor • low coolant sensor • sensor return • fuel le...

  • Page 1891

    Fuel injector sensor—ground provides a low noise ground for the fuel injector sensor only. Engine coolant temperature sensor—msa/ pcm input the 0–5 volt input from this sensor tells the msa and pcm the temperature of the engine coolant. Based on the voltage received at the msa, it will then determin...

  • Page 1892

    The sensor also generates an rpm signal to the msa. This signal is used as an input for the control of the generator field, vehicle speed control, and instrument panel mounted tachometer. If the engine speed sensor should fail, the system is unable to compensate for the problem and the car will stop...

  • Page 1893

    To the msa that the previous fixed speed is requested. Speed control operation will start at 50 km/h–142 km/h (35–85 mph). The upper range of operation is not restricted by vehicle speed. Inputs that effect speed control operation are vehicle speed sensor and accelerator pedal position sensor. Refer...

  • Page 1894

    This 12(+) volt, pulse width modulated (duty–cycle) output controls the amount of fuel timing (advance) in the fuel injection pump. The higher the duty- –cycle, the lower the advance. The lower the duty- –cycle, the more advanced the fuel timing. The duty–cycle is determined by the msa from inputs i...

  • Page 1895

    The current draw will drop to approximately 9–12 amps per plug. Total momentary current draw for all four plugs is approximately 100 amps on a cold engine dropping to a total of approximately 40 amps after the plugs are heated. Electrical operation of the glow plugs are con- trolled by the glow plug...

  • Page 1896

    To group 8w for wiring connector and circuitry infor- mation. Repair the wire harness if an open circuit is indicated. (4) after tests are completed, connect electrical connector to sensor. Glow plug test hard starting or a rough idle after starting may be caused by one or more defective glow plugs....

  • Page 1897

    Plug relay circuit is activated when the ignition (key) switch is on, but the engine has yet to be started. Post–heat is the amount of time the glow plug relay circuit is activated after the engine is operating. The glow plug lamp will not be illuminated during the post–heat cycle. Testing: disconne...

  • Page 1898

    • when the msa energizes the asd and other relays, terminal 87 connects to terminal 30. This is the on position. Terminal 87 supplies voltage to the rest of the circuit. Testing the following procedure applies to the asd and other relays. (1) remove relay from connector before testing. (2) with the ...

  • Page 1899

    Engine speed sensor the engine speed sensor is mounted to the trans- mission bellhousing at the rear of the engine block (fig. 19). Removal (1) disconnect the harness (on the sensor) from the main electrical harness. (2) remove the sensor mounting bolts. (3) remove the sensor. Installation (1) insta...

  • Page 1900

    Glow plugs the glow plugs are located above each fuel injector (fig. 21). Four individual plugs are used. Removal (1) disconnect the negative battery cable at the battery. (2) clean the area around the glow plug with com- pressed air before removal. (3) disconnect electrical connector (fig. 22) at g...

  • Page 1901

    Installation (1) after the pcm electrical connector has been separated from the pcm, inspect the pins for corro- sion, being spread apart, bent or misaligned. Also inspect the pin heights in the connector. If the pin heights are different, this would indicate a pin has separated from the connector. ...

  • Page 1902

    Removal (1) raise and support vehicle. (2) clean the area around the sensor before removal. (3) disconnect the electrical connector from the sensor (fig. 27). (4) remove the sensor mounting bolt (fig. 27). (5) pull the sensor from the speedometer pinion gear adapter for removal. Installation (1) ins...

  • Page 1903: Steering

    Steering contents page page power steering gear . . . . . . . . . . . . . . . . . 9 power steering pump . . . . . . . . . . . . . . . . . 4 power steering . . . . . . . . . . . . . . . . . . . . . . . 1 steering column . . . . . . . . . . . . . . . . . . . . . 21 steering linkage . . . . . . . . . ....

  • Page 1904

    Diagnosis and testing power steering system diagnosis charts steering noise there is some noise in all power steering systems. One of the most common is a hissing sound evident at a standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar to...

  • Page 1905

    Insufficient asst. Or poor return to center condition possible cause correction hard turning or momentary increase in turning effort 1. Tire pressure. 1. Adjust tire pressure. 2. Low fluid level. 2. Fill to proper level. 3. Loose belt. 3. Adjust or replace. 4. Lack of lubrication. 4. Inspect and lub...

  • Page 1906

    Power steering pump index page page description and operation power steering pump . . . . . . . . . . . . . . . . 4 diagnosis and testing power steering pump . . . . . . . . . . . . . . . . 4 pump leakage diagnosis . . . . . . . . . . . . . . 5 service procedures power steering pump—initial operatio...

  • Page 1907

    (6) check fluid level, add fluid as necessary. Start engine again and let idle. (7) gauge should read below 862 kpa (125 psi), if above, inspect the hoses for restrictions and repair as necessary. The initial pressure reading should be in the range of 345-552 kpa (50-80 psi). Caution: the following ...

  • Page 1908

    (4) raise the front wheels off the ground. (5) slowly turn the steering wheel right and left, lightly contacting the wheel stops at least 20 times. (6) check the fluid level add if necessary. (7) lower the vehicle, start the engine and turn the steering wheel slowly from lock to lock. (8) stop the e...

  • Page 1909

    (4) vehicles equipped with speed pro steering, connect actuator harness. (5) install drive belt, refer to group 7 cooling. (6) add power steering fluid. Refer to power steer- ing pump initial operation in this section. Disassembly and assembly pump pulley disassembly (1) remove pump assembly. (2) re...

  • Page 1910

    (5) remove fluid reservoir from pump body. Remove and discard o-ring seal. Assembly (1) lubricate new o-ring seal with mopar power steering fluid or equivalent. (2) install o-ring seal in housing. (3) install reservoir onto housing. (4) slide and tap in reservoir retainer clips until tab locks to ho...

  • Page 1911

    Power steering gear index page page description and operation power steering gear . . . . . . . . . . . . . . . . 9 diagnosis and testing power steering gear leakage diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 11 removal and installation steering gear . . . . . . . . . . . . . . . ...

  • Page 1912

    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 spoo...

  • Page 1913

    Diagnosis and testing power steering gear leakage diagnosis removal and installation steering gear removal (1) place the front wheels in the straight ahead position with the steering wheel centered. (2) remove and cap the pressure and return hoses from the steering gear. (3) remove the column couple...

  • Page 1914

    Disassembly and assembly housing end plug disassembly (1) unseat and remove retaining ring from groove with a punch through the hole in the end of the housing (fig. 5). (2) rotate stub shaft slowly counter-clock- wise to force the end plug out from housing. Caution: do not turn stub shaft any furthe...

  • Page 1915

    (2) coat the oil seals and washer with grease. (3) install the oil seal with a driver and handle. (4) install backup washer. (5) install the retainer ring with snap ring pliers. (6) install dust seal with a driver and handle. (7) install pitman shaft to side cover by screwing shaft in until it fully...

  • Page 1916

    (2) remove adjuster nut with spanner wrench c-4381. (3) remove thrust support assembly out of the housing (fig. 12). (4) pull stub shaft and valve assembly from the housing (fig. 13). (5) remove stub shaft from valve assembly by lightly tapping on a block of wood to loosen shaft. Then disengage stub...

  • Page 1917

    (4) install o-rings and teflon rings over the o-rings on valve body. (5) install o-ring into the back of the stub shaft (fig. 18). (6) install stub shaft and valve assembly in the housing. Line up worm shaft to slots in the valve assembly. (7) install thrust support assembly. Note: if any component ...

  • Page 1918

    Rack piston and worm shaft disassembly (1) remove side cover and pitman shaft. (2) remove housing end plug. (3) remove rack piston plug (fig. 20). (4) turn stub shaft counterclockwise until the rack piston begins to come out of the housing. (5) insert arbor c-4175 into bore of rack piston (fig. 21) ...

  • Page 1919

    (1) check for scores, nicks or burrs on the rack piston finished surface. Slight wear is normal on the worm gear surfaces. (2) install o-ring and teflon ring on the rack pis- ton. (3) install worm shaft in the rack piston and align worm shaft spiral groove with rack piston ball guide hole (fig. 25)....

  • Page 1920

    Adjustments 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 flu...

  • Page 1921

    (5) place the torque wrench in the vertical position on the stub shaft. Rotate the wrench 45 degrees each side of the center and record the highest rotational torque on center (fig. 32). Note: the stub shaft must rotate smoothly without not sticking or binding. (6) the recorded bearing preload shoul...

  • Page 1922

    Specifications power steering gear steering gear type . . . . . . . . . . . . . . . . . . . . . Recirculating ball gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7:1 worm shaft bearing preload . . . . . . . . . . . 0.45-1.13 n·m (4-10 in. Lbs.) pitman shaft overcenter drag new gea...

  • Page 1923

    Steering column index page page general information steering column . . . . . . . . . . . . . . . . . . . . 21 diagnosis and testing ignition switch . . . . . . . . . . . . . . . . . . . . . . 22 removal and installation steering column . . . . . . . . . . . . . . . . . . . . 22 specifications torqu...

  • Page 1924

    Caution: do not attempt to remove the pivot pins to disassemble the tilting mechanism. Do not remove ignition locking link, shaft lock plate or plate retainer. This will damage the column (fig. 2) and (fig. 3). Diagnosis and testing ignition switch test and repair if the ignition switch effort is ex...

  • Page 1925

    (10) remove the interlock cable from the steering column. Refer to group 21 transmission and trans- fer case. (11) remove multi-function switch tamper proof mounting screws and connector screw. Connector screw will stay in the connector. (12) remove the wiring harness from the remain- ing switches a...

  • Page 1926

    (5) install wiring harness connections to steering column. Ensure the wiring is not pinched and all connections are correctly locked in place. (6) install the multi-function switch with the tamper proof mounting screws and install harness connector with screw. (7) install the ignition switch. (8) in...

  • Page 1927

    Steering linkage index page page general information steering linkage . . . . . . . . . . . . . . . . . . . . 25 service procedures steering linkage . . . . . . . . . . . . . . . . . . . . 25 removal and installation drag link . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 pitman arm . . ....

  • Page 1928

    Removal and installation tie rod removal (1) remove the cotter pins and nuts at the steer- ing knuckle and drag link (fig. 1) and (fig. 2). (2) loosen the ball studs with a puller tool to remove the tie rod. (3) if necessary, loosen the end clamp bolts and remove the tie rod ends from the tube. Inst...

  • Page 1929

    (3) remove the drag link from the steering knuckle with a puller tool. Remove the same for tie rod and pitman arm. (4) if necessary, loosen the end clamp bolts and remove the tie rod end from the link. Installation (1) install the drag link adjustment sleeve and tie rod end. Position clamp bolts (fi...

  • Page 1931: Steering

    Steering contents page speed proportional steering . . . . . . . . . . 1 speed proportional steering index page page description and operation power steering gear . . . . . . . . . . . . . . . . 2 speed proportional steering control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 sp...

  • Page 1932

    Speed proportional steering control module the control module is mounted to a bracket on the passenger side of the front cowl panel just left of the steering column (fig. 1). A 14-way connector is attached to the module. The module monitors steer- ing wheel speed and vehicle speed to determine the a...

  • Page 1933

    Diagnosis and testing speed proportional steering for diagnosis and testing procedures refer to the chassis diagnostic manual. Removal and installation steering wheel speed sensor removal (1) disconnect the negative (ground) cable from the battery. (2) remove airbag, refer to group 8m electrical for...

  • Page 1935

    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 . ...

  • Page 1936

    Rear clutch . . . . . . . . . . . . . . . . . . . . . . . . 74 rear servo piston . . . . . . . . . . . . . . . . . . 68 transmission . . . . . . . . . . . . . . . . . . . . . . . . 54 valve body . . . . . . . . . . . . . . . . . . . . . . . . . . 39 cleaning and inspection accumulator . . . . . . . ...

  • Page 1937

    Fig. 1 42/44 re t ransmission zg transmission and transfer case 21 - 3 general information (continued).

  • Page 1938

    Transmission identification transmission identification numbers are stamped on the left side of the case just above the oil pan gas- ket surface (fig. 2). Refer to this information when ordering replacement parts. Recommended fluid mopar t atf plus, type 7176 automatic transmis- sion fluid is the re...

  • Page 1939

    The solenoid valve regulates line pressure to pro- duce governor pressure. The average current sup- plied to the solenoid controls governor pressure. One amp current produces zero kpa/psi governor pres- sure. Zero amps sets the maximum governor pres- sure. The powertrain control module (pcm) turns o...

  • Page 1940

    Throttle position sensor (tps) the tps provides throttle position input signals to the pcm. This input signal is used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Powertrain control module (pcm) the pcm controls operation of the converter clutch...

  • Page 1941

    The switch valve directs fluid apply pressure to the converter clutch in one position and releases it in the opposite position. It also directs oil to the cooling and lube circuits. The switch valve regulates oil pressure to the torque converter by limiting maximum oil pressure to 130 psi. Overdrive...

  • Page 1942

    Diagnosis and testing automatic transmission diagnosis automatic transmission problems can be a result of poor engine performance, incorrect fluid level, incor- rect linkage or cable adjustment, band or hydraulic control pressure adjustments, hydraulic system mal- functions or electrical/mechanical ...

  • Page 1943

    (3) check for cracked, leaking cooler lines, or loose or missing pressure-port plugs. (4) raise and support vehicle on safety stands, start engine, shift transmission into gear, and note following: (a) if propeller shaft turns but wheels do not, problem is with differential or axle shafts. (b) if pr...

  • Page 1944

    Proper operation of the park/neutral position switch will provide a quick check of shift cable adjustment. Road testing before road testing, be sure the fluid level and con- trol cable adjustments have been checked and adjusted if necessary. Verify that diagnostic trouble codes have been resolved. O...

  • Page 1945

    Pressure tests are performed. Practically any condi- tion can be caused by leaking hydraulic circuits or sticking valves. Unless a malfunction is obvious, such as no drive in d range first gear, do not disassemble the trans- mission. Perform the hydraulic and air pressure tests to help determine the...

  • Page 1946

    (3) move gauge c-3293-sp over to front servo port for this test. (4) have helper start and run engine at 1600 rpm for this test. (5) move transmission shift lever two detents rear- ward from full forward position. This is d range. (6) read pressures on both gauges as transmission throttle lever is g...

  • Page 1947

    Stall test procedure (1) connect tachometer to engine. Position tachom- eter so it can be viewed from driver’s seat. (2) drive vehicle to bring transmission fluid up to normal operating temperature. Vehicle can be driven on road or on chassis dynamometer, if available. (3) check transmission fluid l...

  • Page 1948

    And listen for noise coming from the converter hous- ing. Air testing transmission clutch and band operation air-pressure testing can be used to check transmis- sion front/rear clutch and band operation. The test can be conducted with the transmission either in the vehicle or on the work bench, as a...

  • Page 1949

    Front/rear clutches from coming out when oil pump is removed. (3) remove oil pump and remove pump seal. Inspect pump housing drainback and vent holes for obstructions. Clear holes with solvent and wire. (4) inspect pump bushing and converter hub. If bushing is scored, replace it. If converter hub is...

  • Page 1950

    Condition possible causes correction harsh engagement (from neutral to drive or reverse) 1. Fluid level low 1. Add fluid 2. Throttle linkage misadjusted 2. Adjust linkage - setting may be too long. 3. Mount and driveline bolts loose 3. Check engine mount, transmission mount, propeller shaft, rear sp...

  • Page 1951

    Condition possible causes correction no drive range (reverse ok) 1. Fluid level low. 1. Add fluid and check for leaks if drive is restored. 2. Gearshift linkage/cable loose/ misadjusted. 2. Repair or replace linkage components. 3. Rear clutch burnt. 3. Remove and disassemble transmission and rear cl...

  • Page 1952

    Condition possible causes correction shifts delayed or erratic (shifts also harsh at times) 1. Fluid level low/high. 1. Correct fluid level and check for leaks if low. 2. Fluid filter clogged. 2. Replace filter. If filter and fluid contained clutch material or metal particles, an overhaul may be nec...

  • Page 1953

    Condition possible causes correction no low gear (moves in 2nd or 3rd gear only) 1. Governor valve sticking. 1. Remove governor, clean, inspect and repair as required. 2. Governor circuit electrical fault. 2. Test with drb and repair as required. 3. Valve body malfunction. 3. Remove, clean and inspe...

  • Page 1954

    Condition possible causes correction buzzing noise 1. Fluid level low 1. Add fluid and check for leaks. 2. Shift cable misassembled. 2. Route cable away from engine and bell housing. 3. Valve body misassembled. 3. Remove, disassemble, inspect valve body. Reassemble correctly if necessary. Replace as...

  • Page 1955

    Condition possible causes correction growling, grating or scraping noises 1. Drive plate broken. 1. Replace. 2. Torque converter bolts hitting dust shield. 2. Dust shield bent. Replace or repair. 3. Planetary gear set broken/seized. 3. Check for debris in oil pan and repair as required. 4. Overrunni...

  • Page 1956

    Condition possible causes correction clunk noise from driveline on closed throttle 4-3 downshift 1. Transmission fluid low. 1. Add fluid. 2. Throttle cable misadjusted. 2. Adjust cable. 3. Overdrive clutch select spacer wrong spacer. 3. Replace overdrive piston thrust plate spacer. 3-4 upshift occur...

  • Page 1957

    Condition possible causes correction slips in overdrive fourth gear 1. Fluid level low. 1. Add fluid and check for leaks. 2. Overdrive clutch pack worn. 2. Remove overdrive unit and rebuild clutch pack. 3. Overdrive piston retainer bleed orifice blown out. 3. Disassemble transmission, remove retaine...

  • Page 1958

    Condition possible causes correction no reverse (or slips in reverse) 1. Direct clutch pack (front clutch) worn. 1. Disassemble unit and rebuild clutch pack. 2. Rear band misadjusted. 2. Adjust band. 3. Front clutch malfunctioned/burned. 3. Air-pressure test clutch operation. Remove and rebuild if n...

  • Page 1959

    Service procedures fluid level check transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the tran...

  • Page 1960

    Inspection inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompa- nied by slipping condition or shift lag. If fluid and pan are contaminated with excessive...

  • Page 1961

    (1) disconnect the from cooler line at the trans- mission and place a collecting container under the disconnected line. (2) run the engine at curb idle speed, with the shift selector in neutral. (3) if the fluid flow is intermittent or takes more than 20 seconds to collect one quart, the cooler shou...

  • Page 1962

    Aluminum thread repair damaged or worn threads in the aluminum tran- saxle case and valve body can be repaired by the use of heli-coils, or equivalent. This repair consists of drilling out the worn-out damaged threads. Then tap the hole with a special heli-coil tap, or equivalent, and installing a h...

  • Page 1963

    (24) carefully work transmission and torque con- verter assembly rearward off engine block dowels. (25) hold torque converter in place during trans- mission removal. (26) lower transmission and remove assembly from under the vehicle. (27) to remove torque converter, carefully slide torque converter ...

  • Page 1964

    (2) place a suitable drain pan under the converter housing end of the transmission. 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 torqu...

  • Page 1965

    Speedometer adapter rear axle gear ratio and tire size determine speed- ometer pinion requirements. Removal (1) raise vehicle. (2) disconnect wires from vehicle speed sensor. (3) remove adapter clamp and screw (fig. 21). (4) remove speed sensor and speedometer adapter as assembly. (5) remove speed s...

  • Page 1966

    Gearshift cable removal (1) shift transmission into park. (2) remove shift lever bezel and necessary console parts for access to shift lever assembly. (3) disconnect cable at shift lever and feed cable through dash panel opening to underside of vehicle. (4) raise vehicle. (5) disengage cable eyelet ...

  • Page 1967

    (3) snap btsi cable solenoid tie strap into hole in steering column tube. (4) route btsi cable into two clips on carpet pad. (5) snap electrical connector from brake light switch into btsi cable solenoid housing. (6) snap btsi cable adjuster ears into floor shifter bracket and attach cable end fitti...

  • Page 1968

    Valve body the valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. Refer to disassembly and assembly section for proper proce- dures. The only replaceable valve body com...

  • Page 1969

    (11) lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body (fig. 31). Installation (1) check condition of o-ring seals on valve body harness connector (fig. 32). Replace seals on connec- tor body if cut or worn. (2) check condition of manual lever shaf...

  • Page 1970

    The cooler lines and fittings are not serviceable. Damaged fittings or cooler lines are to be replaced as assemblies. Removal (1) if fitting and cooler line are covered with dirt, mud, or grease, clean fitting and cooler line with mopar t spray type carburetor or brake cleaner. (2) disengage retaine...

  • Page 1971

    (12) remove and retain overdrive piston thrust bearing. Bearing may remain on piston or in clutch hub during removal. (13) position drain pan on workbench. (14) place overdrive unit over drain pan. Tilt unit to drain residual fluid from case. (15) examine fluid for clutch material or metal fragments...

  • Page 1972

    (15) connect speed sensor and overdrive wires. (16) align and install propeller shaft. (17) if valve body was also removed, adjust bands, install valve body and install transmission oil pan and gasket. Overdrive housing bushing removal (1) remove overdrive housing yoke seal. (2) insert remover 6957 ...

  • Page 1973

    Disassembly and assembly valve body remove the valve body from the transmission, refer to removal and installation procedures section in this 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...

  • Page 1974

    Ing (fig. 48). Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. (10) unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate (fig. 49). (11) turn valve body over and remove screws that attach overdrive/converter ...

  • Page 1975

    (12) remove solenoid and harness assembly from valve body (fig. 51). (13) remove boost valve cover (fig. 52). (14) remove boost valve retainer, valve spring and boost valve (fig. 53). (15) secure detent ball and spring with retainer tool 6583 (fig. 54). (16) remove park rod e-clip and separate rod f...

  • Page 1976

    (17) remove e-clip and washer that retains throt- tle lever shaft in manual lever (fig. 56). (18) remove manual lever and throttle lever (fig. 57). Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. (19) position pencil magnet next to d...

  • Page 1977

    (21) remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring (fig. 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 housing over and ...

  • Page 1978

    (29) turn valve body over so lower housing is facing upward (fig. 67). In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. (30) remove screws attaching valve body lower housing to upper housing and transfer ...

  • Page 1979

    (3) remove e-clip that secures shuttle valve sec- ondary spring on valve stem (fig. 72). (4) remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides (fig. 73). (5) remove boost valve retainer, spring and valve if not previously removed. (6) remove throttle plug and 1...

  • Page 1980

    Fig. 73 shuttle and boost valve components spring retainer boost valve boost valve plug spring guides 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 valv...

  • Page 1981

    Valve body lower housing disassembly (1) remove timing valve cover. (2) remove 3-4 timing valve and spring. (3) remove 3-4 quick fill valve, spring and plug. (4) remove 3-4 shift valve and spring. (5) remove converter clutch valve, spring and plug (fig. 75). (6) remove converter clutch timing valve,...

  • Page 1982

    Lower housing assembly (1) lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid (fig. 75). (2) install 3-4 timing valve spring and valve in lower housing. (3) install 3-4 quick fill valve in lower housing. (4) install 3-4 quick fill valve spring and plug in h...

  • Page 1983

    Upper and lower housing assembly (1) position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing (fig. 80). Seven check balls are used. The single large check ball is approxi- mately 8.7 mm (11/32 in.) diameter. The remaining 6 check balls ...

  • Page 1984

    (6) install limit valve housing and cover plate. Tighten screws to 4 n·m (35 in. Lbs.). (7) install shuttle valve as follows: (a) insert plastic guides in shuttle valve second- ary spring and install spring on end of valve. (b) install shuttle valve into housing. (c) hold shuttle valve in place. (d)...

  • Page 1985

    Fig. 85 upper housing control valve locations fig. 86 upper housing shift valve and pressureplug locations zg transmission and transfer case 21 - 51 disassembly and assembly (continued).

  • Page 1986

    Boost valve tube and brace assembly (1) position valve body assembly so lower housing is facing upward (fig. 87). (2) lubricate tube ends and housing ports with transmission fluid or petroleum jelly. (3) start tube in lower housing port first. Then swing tube downward and work opposite end of tube i...

  • Page 1987

    Valve body final assembly and adjustment (1) install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 n·m (35 in. Lbs.) torque. (2) insert manual lever detent spring in upper housing. (3) position detent ball on end of spring. Then hold detent ball and spring in d...

  • Page 1988

    Governor body, sensor and solenoid assembly (1) turn valve body assembly over so accumulator side of transfer plate is facing down. (2) install new o-rings on governor pressure sole- noid and sensor (fig. 96). (3) lubricate solenoid and sensor o-rings with clean transmission fluid. (4) install gover...

  • Page 1989

    (4) remove shift and throttle levers from valve body manual lever shaft. (5) place transmission in horizontal position. (6) remove transmission oil pan and gasket. (7) remove filter from valve body (fig. 101). Keep filter screws separate from other valve body screws. Filter screws are longer and sho...

  • Page 1990

    (11) remove accumulator piston and inner and outer springs (fig. 104). (12) remove pump oil seal with suitable pry tool or slide-hammer mounted screw. (13) loosen front band adjusting screw locknut 4-5 turns. Then tighten band adjusting screw until band is tight around front clutch retainer. This pr...

  • Page 1991

    (19) remove front band lever (fig. 107). (20) remove front band lever shaft plug, if neces- sary, from converter housing. (21) remove front band lever shaft. (22) remove front and rear clutch units as assem- bly. Grasp input shaft, hold clutch units together and remove them from case (fig. 108). (23...

  • Page 1992

    (25) remove output shaft thrust plate from inter- mediate shaft hub (fig. 111). (26) slide front band off driving shell (fig. 112) and remove band from case. (27) remove planetary geartrain as assembly (fig. 113). Support geartrain with both hands during removal. Do not allow machined surfaces on in...

  • Page 1993

    Servo bore can be scratched or nicked if care is not exercised. (35) remove compressor tools and remove front servo rod guide, spring and servo piston. (36) compress rear servo spring retainer about 1/16 inch with valve spring compressor c-3422-b (fig. 117). (37) remove rear servo spring retainer sn...

  • Page 1994

    (1) install rear servo piston, spring and retainer (fig. 118). Install spring on top of servo piston and install retainer on top of spring. (2) install front servo piston assembly, servo spring and rod guide (fig. 119). (3) compress front/rear servo springs with valve spring compressor c-3422-b and ...

  • Page 1995

    (7) install snap ring that secures low-reverse drum to hub of overdrive piston retainer (fig. 123). (8) install rear band lever and pivot pin (fig. 124). Align lever with pin bores in case and push pivot pin into place. (9) install planetary geartrain assembly (fig. 125.) fig. 122 installing low-rev...

  • Page 1996

    (10) install thrust plate on intermediate shaft hub (fig. 126). Use petroleum jelly to hold thrust plate in place. (11) check seal ring on rear clutch retainer hub and seal rings on input shaft (fig. 127). Also verify that shaft seal rings are installed in sequence shown. (12) install rear clutch th...

  • Page 1997

    (14) coat intermediate shaft thrust washer with petroleum jelly. Then install washer in rear clutch hub (fig. 130). Use enough petroleum jelly to hold washer in place. Be sure grooved side of washer faces rearward (toward output shaft) as shown. Also note that washer only fits one way in clutch hub....

  • Page 1998

    (22) tighten band adjusting screw until band just grips clutch retainer. Verify that front/rear clutches are still seated before continuing. (23) check seal rings on reaction shaft support hub. Verify that seal rings are hooked together and that front clutch thrust washer is properly positioned (fig...

  • Page 1999

    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 t...

  • Page 2000

    (2) remove the overdrive piston retainer bolts. (3) remove overdrive piston retainer. (4) remove case gasket. (5) mark the position of the overrunning clutch cam in the case (fig. 142). (6) remove the overrunning clutch cam bolts. (7) remove the overrunning clutch cam. Assembly (1) examine bolt hole...

  • Page 2001

    Bolt into each bolt hole. Adjust clutch cam position if necessary. (5) install and tighten overrunning clutch cam bolts to 17 n·m (13 ft. Lbs.) torque. Note that clutch cam bolts are shorter than piston retainer bolts. (6) install new gasket at rear of transmission case. Use petroleum jelly to hold ...

  • Page 2002

    Rear servo piston disassembly (1) remove small snap ring and remove plug and spring from servo piston (fig. 149). (2) remove and discard servo piston seal ring. (3) lubricate piston and guide seals with petro- leum jelly. Lubricate other servo parts with mopar atf plus transmission fluid. Assembly (...

  • Page 2003

    (6) if pump seal was not removed during transmis- sion disassembly, remove seal with punch and ham- mer. (7) remove front clutch thrust washer from sup- port hub (fig. 154). Oil pump bushing replacement (1) remove pump bushing with tool handle c-4171 and bushing remover sp-3551 from tool set c-3887-...

  • Page 2004

    Inspection (1) clean pump and support components with sol- vent and dry them with compressed air. (2) check condition of the seal rings and thrust washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, broken, or severely worn. (3) inspect the pump and suppor...

  • Page 2005

    (9) align reaction support on pump housing. Use alignment marks made at disassembly. Or, rotate support until bolt holes in support and pump housing are all aligned (holes are offset for one-way fit). (10) install all bolts that attach support to pump housing. Then tighten bolts finger tight. (11) t...

  • Page 2006

    Disassembly (1) remove waved snap ring and remove pressure plate, clutch plates and clutch discs (fig. 163). (2) compress clutch piston spring with compressor tool c-3575-a (fig. 164). Be sure legs of tool are seated squarely on spring retainer before compress- ing spring. (3) remove retainer snap r...

  • Page 2007

    Caution: never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. (5) position spring in clutch piston (fig. 166). (6) position spring retainer on top of piston spring (fig. 167). Make sure retainer is properly installed. Small raised tabs should be fa...

  • Page 2008

    Rear clutch disassembly (1) remove fiber thrust washer from forward side of clutch retainer. (2) remove input shaft front/rear seal rings. (3) remove selective clutch pack snap ring (fig. 168). (4) remove top pressure plate, clutch discs, steel plates, bottom pressure plate and wave snap ring and wa...

  • Page 2009

    (6) install new seals on clutch piston. Be sure lip of each seal faces interior of clutch retainer. (7) lubricate lip of piston seals with generous quantity of mopar t door ease. Then lubricate retainer hub and bore with light coat of transmission fluid. (8) install clutch piston in retainer. Use tw...

  • Page 2010

    (d) lift the pressure plate until it contacts the snap-ring and record the dial indicator reading. Clearance should be 0.64 - 1.14 mm (0.025 - 0.045 in.). If clearance is incorrect, steel plates, discs, selec- tive snap ring and pressure plates may have to be changed. The selective snap ring thickne...

  • Page 2011

    Planetary geartrain/output shaft disassembly (1) remove planetary snap ring (fig. 176). (2) remove front annulus and planetary assembly from driving shell (fig. 176). (3) remove snap ring that retains front planetary gear in annulus gear (fig. 177). (4) remove tabbed thrust washer and tabbed thrust ...

  • Page 2012

    Assembly (1) lubricate output shaft and planetary compo- nents with transmission fluid. Use petroleum jelly to lubricate and hold thrust washers and plates in posi- tion. (2) assemble rear annulus gear and support if dis- assembled. Be sure support snap ring is seated and that shoulder-side of suppo...

  • Page 2013

    (11) align rear thrust plate on driving shell and install sun gear lock ring. Be sure ring is fully seated in sun gear ring groove (fig. 188). (12) install assembled driving shell and sun gear on output shaft (fig. 189). (13) install rear thrust washer on front planetary gear (fig. 190). Use enough ...

  • Page 2014

    (14) install front planetary gear on output shaft and in driving shell (fig. 191). (15) install front thrust washer on front planetary gear. Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated. (16) assemble front annulus gear and support, if necessary. Be ...

  • Page 2015

    (21) install planetary selective snap ring with snap ring pliers (fig. 195). Be sure ring is fully seated. (22) turn planetary geartrain assembly over so driving shell is facing workbench. Then support geartrain on wood block positioned under forward end of output shaft. This allows geartrain compo-...

  • Page 2016

    (2) remove overdrive piston thrust bearing (fig. 198). Overdrive piston disassembly (1) remove overdrive piston thrust plate (fig. 199). Retain thrust plate. It is a select fit part and may possibly be reused. (2) remove intermediate shaft spacer (fig. 200). Retain spacer. It is a select fit part an...

  • Page 2017

    (2) remove overdrive clutch pack (fig. 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 position of clutch pack components for assembly reference (fig. 204). Overdrive geartrain disassembly (...

  • Page 2018

    (2) remove overdrive clutch reaction snap ring (fig. 206). Note that snap ring is located in same groove as wave spring. (3) remove torx head screws that attach access cover and gasket to overdrive case (fig. 207). (4) remove access cover and gasket (fig. 208). (5) expand output shaft bearing snap r...

  • Page 2019

    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 hydraul...

  • Page 2020

    (2) remove sun gear and spring plate. Then remove planetary thrust bearing and planetary gear (fig. 217). (3) remove overrunning clutch assembly with expanding type snap ring pliers (fig. 218). Insert pli- ers into clutch hub. Expand pliers to grip hub splines and remove clutch with counterclockwise...

  • Page 2021

    (7) remove direct clutch drum rear retaining ring (fig. 220). (8) remove direct clutch drum outer retaining ring (fig. 221). (9) mark annulus gear and output shaft for assem- bly alignment reference (fig. 222). Use punch or scriber to mark gear and shaft. (10) remove snap ring that secures annulus g...

  • Page 2022

    Overdrive unit assembly geartrain and direct clutch assembly (1) soak direct clutch and overdrive clutch discs in mopar t atf plus transmission fluid. Allow discs to soak for 10-20 minutes. (2) install new pilot bushing and clutch hub bush- ing in output shaft if necessary (fig. 225). Lubricate bush...

  • Page 2023

    Way only. Be sure bearing is seated squarely against hub. Reinstall bearing if it does not seat squarely. (10) install overrunning clutch in output shaft (fig. 231). Insert snap ring pliers in hub splines. Expand pliers to grip hub. Then install assembly with counterclockwise, twisting motion. (11) ...

  • Page 2024

    (14) install assembled sun gear, spring plate and thrust bearing (fig. 234). Be sure sun gear and thrust bearing are fully seated before proceeding. (15) mount assembled output shaft, annulus gear, and clutch drum in shop press. Direct clutch spring, hub and clutch pack are easier to install with as...

  • Page 2025

    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 minimu...

  • Page 2026

    (26) slowly release press ram, remove compressor tools and remove geartrain assembly. 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 c...

  • Page 2027

    Gear case assembly (1) position park pawl and spring in case and install park pawl shaft. Verify that end of spring with 90° bend is hooked to pawl and straight end of spring is seated against case. (2) install pawl shaft retaining bolt. Tighten bolt to 27 n·m (20 ft. Lbs.) torque. (3) install park ...

  • Page 2028

    Overdrive clutch assembly (1) install overdrive clutch reaction ring first. Reaction ring is flat with notched ends (fig. 250). (2) install wave spring on top of reaction ring (fig. 251). Reaction ring and wave ring both fit in same ring groove. Use screwdriver to seat each ring securely in groove. ...

  • Page 2029

    Output shaft is not loaded and internal components are moved rearward for accurate measurement. (2) determine correct thickness intermediate shaft spacer as follows: (a) insert special tool 6312 through sun gear, planetary gear and into pilot bushing in output shaft. Be sure tool bottoms against pla...

  • Page 2030

    Overdrive piston assembly (1) install new seals on over drive piston. (2) stand transmission case upright on bellhous- ing. (3) position guide ring 8114-1 on outer edge of overdrive piston retainer. (4) position seal guide 8114-2 on inner edge of overdrive piston retainer. (5) install overdrive pist...

  • Page 2031

    Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matt...

  • Page 2032

    Fig. 258 upper housing v alves, plug, springsand brackets 21 - 98 transmission and transfer case zg cleaning and inspection (continued).

  • Page 2033

    Transmission general information inspect the transmission bushings during overhaul. Bushing condition is important as worn, scored bush- ings contribute to low pressures, clutch slip and accelerated wear of other components. However, do not replace bushings as a matter of course. Replace bushings on...

  • Page 2034

    Replace the front band if distorted, lining is burned, flaking off, or worn to the point where the grooves in the lining material are no longer visible. Inspect the servo components. Replace the springs if collapsed, distorted or broken. Replace the guide, rod and piston if cracked, bent, or worn. D...

  • Page 2035

    Replace the piston spring and wave spring if either part is distorted, warped or broken. Check the lug grooves in the clutch retainer. The clutch and pressure plates should slide freely in the slots. Replace the retainer if the grooves are worn or damaged. Also check action of the check balls in the...

  • Page 2036

    Inspect the planetary gear assembly and the sun gear and bushings. If either the sun gear or the bushings are damaged, replace the gear and bush- ings as an assembly. The gear and bushings are not serviced separately. The planetary carrier and pinions must be in good condition. Also be sure the pini...

  • Page 2037

    • neutral position, engine running and brakes applied- apply forward force on center of shift handle. Transmission should not be able to shift into reverse detent. Transmission throttle valve cable adjustment the transmission throttle valve is operated by a cam on the throttle lever. The throttle le...

  • Page 2038

    (3) release cable adjuster clamp (at transmission end of cable) to unlock cable. (4) unsnap cable from cable mounting bracket on transmission (fig. 266). (5) slide cable eyelet off transmission shift lever. (6) verify transmission shift lever is in park detent by moving lever fully rearward. Last re...

  • Page 2039

    • hold adjusting screw in place and tighten lock- nut to 34 n·m (25 ft. Lbs.) torque. 44re transmission • back off adjusting screw 4 turns. • hold adjusting screw in place and tighten lock- nut to 34 n·m (25 ft. Lbs.) torque. (5) position new gasket on oil pan and install pan on transmission. Tighte...

  • Page 2040

    Hydraulic flow in p ark 21 - 106 transmission and transfer case zg schematics and diagrams (continued).

  • Page 2041

    Hydraulic flow in neutral zg transmission and transfer case 21 - 107 schematics and diagrams (continued).

  • Page 2042

    Hydraulic flow in reverse 21 - 108 transmission and transfer case zg schematics and diagrams (continued).

  • Page 2043

    Hydraulic flow in drive first gear zg transmission and transfer case 21 - 109 schematics and diagrams (continued).

  • Page 2044

    Hydraulic flow in drive second gear 21 - 110 transmission and transfer case zg schematics and diagrams (continued).

  • Page 2045

    Hydraulic flow in drive third gear zg transmission and transfer case 21 - 111 schematics and diagrams (continued).

  • Page 2046

    Hydraulic flow in drive four th gear(conver ter clutch not applied) 21 - 112 transmission and transfer case zg schematics and diagrams (continued).

  • Page 2047

    Hydraulic flow in drive four th gear(conver ter clutch applied) zg transmission and transfer case 21 - 113 schematics and diagrams (continued).

  • Page 2048

    Hydraulic flow in manual low (1) 21 - 114 transmission and transfer case zg schematics and diagrams (continued).

  • Page 2049

    Hydraulic flow in manual second (2) zg transmission and transfer case 21 - 115 schematics and diagrams (continued).

  • Page 2050

    Hydraulic flow during full throttle3–2 downshift (p assing gear) 21 - 116 transmission and transfer case zg schematics and diagrams (continued).

  • Page 2051

    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 fitting, cooler line at trans . . . . . 18 n·m (13 ft. Lbs.) bolt, torque convertor . . . . . . . . . 31 n·m (23 ft. Lbs.) bolt/nut, crossmember ....

  • Page 2052

    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 sh...

  • Page 2053

    Special tools re transmissions spring compressor and alignment shaft—6227 gauge bar—6311 extension housing pilot—c-3288-b pressure gauge—c-3292 pressure gauge—c-3293sp dial indicator—c-3339 spring compressor—c-3422-b zg transmission and transfer case 21 - 119.

  • Page 2054

    Puller, slide hammer—c-3752 gauge, throttle setting—c-3763 seal installer—c-3860–a seal remover—c-3985-b installer—c-3995-a universal handle—c-4171 seal installer—c-4193-a dial caliper—c-4962 21 - 120 transmission and transfer case zg special tools (continued).

  • Page 2055

    Bushing remover/installer set—c-3887-j nut, bushing remover—sp-1191,from kit c-3887-j cup, bushing remover—sp-3633,from kit c-3887-j remover, bushing—sp-3551 installer, bushing—sp-5117 remover, bushing—sp-5324 installer, bushing—sp-5325 compressor, spring—c-3575-a zg transmission and transfer case 2...

  • Page 2056

    Gauge—6312 adapter—c-3705 flusher—6906 installer—8114 remover—6957 installer—6951 retainer—6583 21 - 122 transmission and transfer case zg special tools (continued).

  • Page 2057

    Nv242 transfer case index page page general information nv242 transfer case . . . . . . . . . . . . . . . . 123 recommended lubricant and fill level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 transfer case identification . . . . . . . . 124 diagnosis and testing nv...

  • Page 2058

    Shift mechanism operating ranges are selected with a floor mounted shift lever. The shift lever is connected to the trans- fer case range lever by an adjustable linkage rod. A straight line shift pattern is used. Range positions are marked on the shifter bezel cover plate, or on the shift knob. Tran...

  • Page 2059

    Diagnosis and testing nv242 diagnosis condition possible cause correction transfer case difficult to shift or will not shift into desired range (1) transfer case external shift linkage binding. (1) lubricate, repair or replace linkage, or tighten loose components as necessary. (2) insufficient or in...

  • Page 2060

    Removal and installation transfer case removal (1) shift transfer case into neutral. (2) raise vehicle. (3) drain transfer case lubricant. (4) mark front and rear propeller shaft yokes for alignment reference. (5) support transmission with jack stand. (6) remove rear crossmember, or skid plate. (7) ...

  • Page 2061

    (10) install rear crossmember, or skid plate. Tighten crossmember bolts to 41 n·m (30 ft. Lbs.) torque. (11) remove transmission jack and support stand. (12) connect shift rod to transfer case range lever. (13) adjust transfer case shift linkage. (14) lower vehicle and verify transfer case shift ope...

  • Page 2062

    (6) remove speedometer pinion from adapter. Replace pinion if chipped, cracked, or worn. (7) inspect sensor and adapter o-rings (fig. 5). Remove and discard o-rings if worn or damaged. (8) inspect terminal pins in speed sensor. Clean pins with mopar t electrical spray cleaner if dirty or oxidized. R...

  • Page 2063

    (b) start seal in bore with light taps from ham- mer (fig. 8). Once seal is started, continue tapping seal into bore until installer tool seats against case. Disassembly and assembly nv242 transfer case disassembly rear retainer removal (1) remove output shaft boot. Spread band clamp that secures bo...

  • Page 2064

    (8) remove rear retainer. Tap retainer with mallet and pry upward to break sealer bead. Then slide retainer off case and output shaft (fig. 14). (9) remove rear bearing o.D. Retaining ring with snap ring pliers. Then tilt pump and slide it off out- put shaft (fig. 15) (10) remove pickup tube o-ring ...

  • Page 2065

    Case. Then pry upward to break sealer 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 oil pickup tube and screen from rear case (fig. 19). Yoke and range lever removal (1) remove front yoke nut: (a) move range...

  • Page 2066

    Shift forks and mainshaft removal and disassembly (1) remove shift detent plug, spring and pin (fig. 26). (2) remove seal plug from low range fork lockpin access hole. Then move shift sector to align low range fork lockpin with access hole. (3) remove range fork lockpin with size number one easy-out...

  • Page 2067

    (e) in one motion, pull upward and turn the t-handle counter-clockwise to remove the lock-pin. (4) remove shift rail by pulling it straight up and out of fork (fig. 27). (5) remove mode fork and mainshaft as assembly (fig. 28). (6) remove mode shift sleeve and mode fork assembly from mainshaft (fig....

  • Page 2068

    (8) remove clutch shaft thrust ring (fig. 31). (9) remove intermediate clutch shaft (fig. 32). (10) remove differential snap-ring (fig. 33). (11) remove differential (fig. 34). (12) remove differential needle bearings and both needle bearing thrust washers from mainshaft. Fig. 31 clutch shaft thrust...

  • Page 2069

    (13) slide low range fork pin out of shift sector slot (fig. 35). (14) remove low range fork and hub (fig. 36). (15) remove shift sector (fig. 37). (16) remove shift sector bushing and o-ring (fig. 38). Input gear/low range assembly removal and disassembly (1) remove front bearing retainer bolts. (2...

  • Page 2070

    (6) remove input gear retainer, thrust washers and input gear from low range gear (fig. 43). (7) inspect low range annulus gear (fig. 44). Gear is not a serviceable component. If damaged, replace gear and front case as assembly. (8) remove oil seals from following components: • front bearing retaine...

  • Page 2071

    (4) separate top case from bottom case. Use slots in case halves to pry them apart (fig. 45). (5) remove thrust washers and planet gears from case pins (fig. 46). Fig. 43 low range gear disassembly thrust washers low range gear input gear retainer fig. 44 inspecting low range annulus gear low range ...

  • Page 2072

    (6) remove mainshaft and sprocket gears from bottom case (fig. 47). Note gear position for reference before separating them. Assembly lubricate transfer case components with automatic transmission fluid or petroleum jelly (where indi- cated) during assembly. Caution: the bearing bores in various tra...

  • Page 2073

    (5) install new front output shaft oil seal with installer 6952-a (fig. 51). (6) remove input gear bearing with tool handle c-4171 and remover c-4210 (fig. 52). (7) install snap-ring on new input gear bearing. (8) install new input gear bearing with tool han- dle c-4171 and remover c-4210. Install b...

  • Page 2074

    (10) install new pilot bearing with installer 8128 and handle c-4171 (fig. 55). (11) install new seal in front bearing retainer with installer 7884 (fig. 56). (12) remove output shaft rear bearing with the screw and jaws from remover l-4454 and cup 8148 (fig. 57). (13) install new bearing with tool ...

  • Page 2075

    (14) install new seal in oil pump feed housing with special tool 7888 (fig. 59). (15) install new pickup tube o-ring in oil pump (fig. 60). Differential assembly (1) lubricate differential components with auto- matic transmission fluid. (2) install sprocket gear in differential bottom case (fig. 61)...

  • Page 2076

    Input gear/low range assembly (1) assemble low range gear, input gear thrust washers, input gear and input gear retainer (fig. 64). (2) install low range gear snap ring (fig. 65). (3) lubricate input gear and low range gears with automatic transmission fluid. (4) start input gear shaft into front ca...

  • Page 2077

    Shift forks and mainshaft installation (1) install new sector shaft o-ring and bushing (fig. 68). (2) install shift sector. (3) install new pads on low range fork, if neces- sary, (fig. 69). (4) assemble low range fork and hub (fig. 69). (5) position low range fork and hub in case. Be sure low range...

  • Page 2078

    (6) install first mainshaft bearing spacer on main- shaft (fig. 71). (7) install bearing rollers on mainshaft (fig. 71). Coat bearing rollers with generous quantity of petroleum jelly to hold them in place. (8) install remaining bearing spacer on mainshaft (fig. 71). Do not displace any bearings whi...

  • Page 2079

    (12) install clutch shaft thrust washer (fig. 75). (13) install clutch shaft snap-ring (fig. 76). (14) inspect mode fork assembly (fig. 77). Replace pads and bushing if necessary. Replace fork tube if bushings inside tube are worn or damaged. Also check springs and slider bracket (fig. 77). Replace ...

  • Page 2080

    (17) rotate mode fork pin into shift sector slot. (18) install shift rail (fig. 80). Be sure rail is seated in both shift forks. (19) rotate shift sector to align lockpin hole in low range fork with access hole in case. (20) insert an easy-out in range fork lockpin to hold it securely for installati...

  • Page 2081

    Front output shaft and drive chain installation (1) install front output shaft (fig. 83). (2) install drive chain (fig. 83). Engage chain with front output shaft sprocket teeth. (3) install drive sprocket (fig. 83). Engage drive sprocket teeth with chain. Then engage sprocket splines with mainshaft ...

  • Page 2082

    Washer under each bolt used at case dowel locations. Rear retainer installation (1) remove rear bearing in retainer using installer 8128 and handle c-4171. (2) install rear bearing in retainer with tools c-4171 and 5064 (fig. 87). (3) install rear bearing o.D. Retaining ring with snap-ring pliers (f...

  • Page 2083

    (4) install yoke on front shaft. Secure yoke with new nut. Cleaning and inspection nv242 transfer case clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases and retainers with a scraper and all purpose cleaner. Use compressed air to remove s...

  • Page 2084

    Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or damage is evident. Rear retainer/bearing/ seal/slinger/ boot inspect the retainer components (fig. 94). Replace the bearing if rough or noisy. Check the retainer for cracks or wear in the b...

  • Page 2085

    Low range annulus gear inspect annulus gear condition carefully. The gear is only serviced as part of the front case. If the gear is damaged, it will be necessary to replace the gear and front case as an assembly. Do not attempt to remove the gear (fig. 96). Front-rear cases and front retainer inspe...

  • Page 2086

    Specifications torque description torque plug, detent . . . . . . . . . . 16–24 n·m (12–18 ft. Lbs.) bolt, diff. Case . . . . . . . . 17–27 n·m (15–24 ft. Lbs.) plug, drain/fill . . . . . . . . 40–45 n·m (30–40 ft. Lbs.) bolt, front brg. Retainer . 16–27 n·m (12–20 ft. Lbs.) bolt, case half . . . . ...

  • Page 2087

    Installer—8128 installer—5066 installer—6952-a remover—l-4454 cup—8148 seal protector—6992 installer, input gear bearing—7829-a installer, seal—7884 zg transmission and transfer case 21 - 153 special tools (continued).

  • Page 2088

    Installer, pump housing seal—7888 installer, bearing—8033-a installer, boot clamp—c-4975-a 21 - 154 transmission and transfer case zg special tools (continued).

  • Page 2089

    Nv249 transfer case index page page general information general information . . . . . . . . . . . . . . . 155 recommended lubricant and fill level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 transfer case identification . . . . . . . . 155 diagnosis and testing nv24...

  • Page 2090

    Diagnosis and testing nv249 diagnosis condition possible cause correction transfer case difficult to shift or will not shift into desired range (a) vehicle speed too great to permit shifting. (a) stop vehicle and shift into desired range. Or reduce speed to 3-4 km/h (2-3 mph) before attempting to sh...

  • Page 2091

    Removal and installation transfer case removal (1) shift transfer case into neutral. (2) raise vehicle. (3) drain transfer case lubricant. (4) mark front and rear propeller shaft yokes for alignment reference. (5) support transmission with jack stand. (6) remove rear crossmember, or skid plate. (7) ...

  • Page 2092

    Shift lever removal (1) shift transfer case into 4l. (2) raise vehicle. (3) loosen adjusting trunnion locknut and slide shift rod out of trunnion (fig. 4). If rod lacks enough travel to come out of trunnion, push trunnion out of torque shaft. (4) lower vehicle. (5) remove console. Refer to group 23,...

  • Page 2093

    Installation and indexing (1) thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer oper- ation. (2) install new o-rings on speed sensor and speed- ometer adapter (fig. 5), if necessary. (3) lubricate sensor and a...

  • Page 2094

    Front output shaft seal removal (1) raise vehicle. (2) remove front propeller shaft. Refer to group 3, differential and driveline, for proper procedure. (3) remove front output shaft yoke. (4) remove seal from front case with pry tool (fig. 7). Installation (1) install new front output seal in front...

  • Page 2095

    Disassembly and assembly nv249 transfer case disassembly position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case. Rear retainer and oil pump removal (1) remove the speedometer adapter. (2) remove rear retainer bolts (fig. 12). (3) remove rear bearing loca...

  • Page 2096

    (7) remove rear bearing snap-ring. (8) remove rear bearing. Note position of bearing locating ring groove for assembly reference. (9) disengage oil pickup tube from oil pump and remove oil pump assembly (fig. 18). (10) remove pick-up tube o-ring from oil pump (fig. 19), if necessary. Do not disassem...

  • Page 2097

    (4) remove seal washer from front output shaft. Discard washer as it should not be reused. (5) remove nut and washer that attach range lever to sector shaft. Then move sector to neutral position and remove range lever from shaft (fig. 23). Front output shaft and drive chain removal (1) support trans...

  • Page 2098

    (5) remove oil pickup tube from rear case (fig. 27). (6) remove drive gear snap-ring (fig. 28). (7) disengage drive gear (fig. 28). Pry gear upward and off mainshaft as shown. (8) remove front output shaft, drive chain and drive gear as assembly (fig. 28). Shift forks and mainshaft removal (1) remov...

  • Page 2099

    Input gear/low range assembly removal (1) turn front case on side so front bearing retainer is accessible. (2) remove front bearing retainer bolts (fig. 34). (3) remove front bearing retainer as follows: (a) loosen retainer with flat blade screwdriver to break sealer bead. To avoid damaging case and...

  • Page 2100

    Input and low range gear disassembly (1) remove snap-ring that retains input gear in low range gear (fig. 38). (2) remove retainer (fig. 39). (3) remove front tabbed thrust washer (fig. 40). (4) remove input gear (fig. 41). (5) remove rear tabbed thrust washer from low range gear (fig. 42). Assembly...

  • Page 2101

    Bearing and seal installation (1) remove front output shaft seal from front case with pry tool (fig. 43). (2) remove snap-ring that retains front output shaft bearing in front case (fig. 44). (3) using tool 6953, remove bearing from front case (fig. 45). (4) using tool 6953, install new bearing. (5)...

  • Page 2102

    (8) install new bearing with tool handle c-4171 and installer 5066 (fig. 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) using remover c-4210 and handle c-4171, drive input shaft bearing from inside the annulus gear...

  • Page 2103

    (13) remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer (fig. 52). (14) install new pilot bearing with installer 8128 and handle c-4171 (fig. 53). (15) remove front bearing retainer seal w...

  • Page 2104

    Input and low range gear assembly (1) lubricate gears and thrust washers (fig. 55) with recommended transmission fluid. (2) install first thrust washer in low range gear (fig. 55). Be sure washer tabs are properly aligned in gear notches. (3) install input gear in low range gear. Be sure input gear ...

  • Page 2105

    Shift forks and mainshaft installation (1) install new sector shaft o-ring and bushing (fig. 59). (2) install shift sector (fig. 60). (3) install new pads on range fork (fig. 61), if nec- essary. (4) install clutch sleeve in range fork (fig. 61). (5) install assembled range fork and clutch sleeve (f...

  • Page 2106

    Front output shaft and drive chain installation (1) lubricate front output shaft-sprocket assembly, drive chain and drive sprocket with transmission fluid. (2) assemble drive chain, drive sprocket and front output shaft (fig. 64). (3) start drive sprocket on mainshaft. (4) guide front shaft into bea...

  • Page 2107

    (2) install range lever, washer and locknut on sec- tor shaft (fig. 72). Tighten locknut to 27-34 n·m (20-25 ft. Lbs.) torque. (3) install new seal washer on front output shaft (fig. 74). (4) lubricate yoke hub with transmission fluid and install yoke on front shaft. (5) install new seal washer on f...

  • Page 2108

    (7) tighten yoke nut to 122-176 n·m (90-130 ft. Lbs.) torque. Use tool c-3281, or similar tool to hold yoke while tightening yoke nut. Viscous coupler (1) install coupling on mainshaft (fig. 75). (2) install coupling retaining snap-ring first (fig. 75). Be sure snap ring is fully seated before proce...

  • Page 2109

    Final assembly (1) install drain plug. Tighten plug to 41-54 n·m (30-40 ft. Lbs.) torque. (2) level transfer case and fill it with mopar dexron ii automatic transmission fluid. Correct fill level is to bottom edge of fill plug hole. (3) install and tighten fill plug to 41-54 n·m (30-40 ft. Lbs.) tor...

  • Page 2110

    Input and low range gears inspect the low range gear pinions and pinion pins. Replace the low range gear if any of the pins or pin- ions are worn or damaged. Inspect the thrust washers, retainer, and snap- ring. Replace the snap-ring if bent, or distorted. Replace the thrust washers and retainer if ...

  • Page 2111

    (2) raise vehicle on hoist that will allow all four wheels to rotate freely. (3) loosen trunnion lock bolt (fig. 84). Loosen bolt enough so selector rod slides freely in trunnion. (4) verify that shift lever on transfer case is in neutral position. (5) tighten trunnion lock bolt to 11-20 n·m (96-180...

  • Page 2112

    Special tools nv249 transfer case installer—5066 installer—6952-a installer—6953 remover—6957 installer—c-3995-a handle—c-4171 installer—8145 remover—c-4210 21 - 178 transmission and transfer case zg.

  • Page 2113

    Remover—l-4454 cup—8148 installer—8128 installer—7884 zg transmission and transfer case 21 - 179 special tools (continued).

  • Page 2115

    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 is a 5–speed, synchromesh, manual transmission. Fifth gear i...

  • Page 2116

    Transmission shift pattern the ax 15 shift pattern is shown in (fig. 3). First and second and third and fourth gear ranges are in line for improved shifting. Fifth and reverse gear ranges are also in line at the extreme right of the pattern (fig. 3). The ax 15 is equipped with a reverse lockout mech...

  • Page 2117

    Severe, it may also contaminate the clutch disc caus- ing slip, grab and chatter. Transmissions filled from air or electrically pow- ered lubricant containers can be under filled. This generally happens when the container delivery mech- anism is improperly calibrated. Always check the lubricant leve...

  • Page 2118

    11. Disconnect the transfer case linkage and vehi- cle speed sensor electrical connector and vent tube hose (fig. 8). 12. Reposition the adjustable jackstand under the engine. 13. Place a transmission jack under the transmis- sion and secure the transmission with safety chains. 14. Remove the rear t...

  • Page 2119

    Fig. 10 transmission to engine mounting fig. 11 clutch housing to transmission fig. 12 fill plug location zg transmission and transfer case 21 - 5 removal and installation (continued).

  • Page 2120

    Specifications torque description torque clutch housing to engine top (2) bolts . . . . . . . . . . . . 36.6 n·m (27 ft. Lbs.) clutch housing to engine mid-point (2) bolts . . . . . . . 58.3 n·m (43 ft. Lbs.) clutch housing to engine bottom (2) bolts . . . . . . . . . . 74.6 n·m (55 ft. Lbs.) clutch...

  • Page 2121

    Nv231 transfer case general information nv231 transfer case the nv231 is a part-time transfer case with a low range reduction gear system. The nv231 has three operating ranges plus a neutral position. A low range system provides a reduction ratio for increased low speed torque capability. The input ...

  • Page 2122

    Diagnosis and testing nv231 diagnosis 21 - 8 transmission and transfer case zg.

  • Page 2123

    Removal and installation transfer case removal (1) shift transfer case into neutral. (2) raise vehicle. (3) drain transfer case lubricant. (4) mark front and rear propeller shaft yokes for alignment reference. (5) support transmission with jack stand. (6) remove rear crossmember and skid plate, if e...

  • Page 2124

    Installation (1) position shift lever on transmission. Use care when passing the shift lever through the shifter boot to prevent damage to the shifter boot. (2) install bolts to hold shift lever to transmission. (3) install trunnion to shift lever, if necessary. (4) install shift rod to trunnion, if...

  • Page 2125

    Front output shaft seal removal (1) raise vehicle. (2) remove front propeller shaft. Refer to group 3, differential and driveline, for proper procedure. (3) remove front output shaft yoke. (4) remove seal from front case with pry tool (fig. 6). Installation (1) install new front output seal in front...

  • Page 2126

    (3) using installer 8160, drive bushing into retainer until installer seats against case (fig. 9). (4) using installer c-3995-a, install seal in rear retainer (fig. 10). (5) install propeller shaft. (6) verify proper fluid level. (7) lower vehicle. Specifications torque description torque plug, drai...

  • Page 2127: Tires And Wheels

    Tires and wheels contents page page tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 tires index page page description and operation radial-ply tires . . . . . . . . . . . . . . . . . . . . . . 2 replacem...

  • Page 2128

    Radial-ply tires radial-ply tires improve handling, tread life, ride quality and decrease rolling resistance. Radial-ply tires must always be used in sets of four and under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum ...

  • Page 2129

    Weather temperature varies widely. Tire pressure will decreases when the outdoor temperature drops. Inflation pressures specified on the placards are always cold inflation pressure. Cold inflation pres- sure is obtained after the vehicle has not been oper- ated for at least 3 hours. Or the vehicle i...

  • Page 2130

    Tire noise or vibration radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibra- tion, drive the vehicle over a smooth road at varying speeds. Note the effect of accelerati...

  • Page 2131

    (2) break down the tire and remount it 180 degrees on the rim (fig. 8). (3) measure the total indicator runout again. Mark the tire to indicate the high spot. (4) if runout is still excessive, the following proce- dures must be done. • if the high spot is within 101.6 mm (4.0 in.) of the first spot ...

  • Page 2132

    Cleaning and inspection cleaning of tires remove protective coating on tires before delivery of vehicle. The coating could cause deterioration of tires. Remove protective coating by: • applying warm water • letting it soak one minute • scrubbing the coating away with a soft bristle brush. • steam cl...

  • Page 2133

    Wheels index page page description and operation wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 diagnosis and testing tire and wheel runout . . . . . . . . . . . . . . . 8 wheel inspection . . . . . . . . . . . . . . . . . . . . . 7 service procedures tire and wheel balance . ...

  • Page 2134

    Tire and wheel runout radial runout is the difference between the high and low points on the tire or wheel (fig. 2). Lateral runout is the wobble of the tire or wheel. Radial runout of more than 1.5 mm (.060 inch) measured at the center line of the tread may cause the vehicle to shake. Lateral runou...

  • Page 2135

    Note: do not use chrome plated lug nuts with chrome plated wheels. Before installing the wheel, be sure to remove any build up of corrosion on the wheel mounting surfaces. Ensure wheels are installed with good metal-to-metal contact. Improper installation could cause loosening of wheel nuts. This co...

  • Page 2136

    For static imbalance, find location of heavy spot causing imbalance. Counter balance wheel directly opposite the heavy spot. Determine weight required to counterbalance the area of imbalance. Place half of this weight on the inner rim flange and the other half on the outer rim flange (fig. 6) and (f...

  • Page 2137: Body

    Body contents page page body components . . . . . . . . . . . . . . . . . . . . 16 general service information . . . . . . . . . . 1 paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 power sunroof . . . . . . . . . . . . . . . . . . . . . . . 8 seats . . . . . . . . . . . . ....

  • Page 2138

    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 pr...

  • Page 2139

    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...

  • Page 2140

    Stationary glass index page page description and operation safety precautions . . . . . . . . . . . . . . . . . . 4 removal and installation liftgate glass . . . . . . . . . . . . . . . . . . . . . . . 7 quarter window glass . . . . . . . . . . . . . . . 5 windshield . . . . . . . . . . . . . . . . ...

  • Page 2141

    (3) clean inside of windshield with mopar glass cleaner and lint-free cloth. (4) apply clear glass primer 25 mm (1 in.) wide around edge of windshield. Wipe with clean/dry lint- free cloth. (5) apply black-out primer 15 mm (.75 in.) wide on top and sides of windshield and 25 mm (1 in.) on bot- tom o...

  • Page 2142

    (2) separate glass from vehicle. 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 window opening fence should be cleaned of old urethane bond...

  • Page 2143

    Liftgate glass removal (1) cut urethane bonding from around liftgate glass using a suitable sharp cold knife. A pneumatic cutting device can be used if available. (2) separate glass from vehicle. Installation caution: open a window before installing glass. This will avoid pressurizing the passenger ...

  • Page 2144

    Power sunroof index page page general information general information . . . . . . . . . . . . . . . . . 8 removal and installation drain channel . . . . . . . . . . . . . . . . . . . . . . . 10 drive cable locators . . . . . . . . . . . . . . . . 10 drive cables . . . . . . . . . . . . . . . . . . ....

  • Page 2145

    (3) lift rear of adjustment bracket to highest ver- tical position and disengage front of bracket from unit (fig. 4). Installation (1) reverse the preceding operation. Adjust glass as necessary. Fig. 2 drain tube locations fwd index drain tube fwd body drain tube fwd clamp plug/adapter rear left sid...

  • Page 2146

    Drain channel removal (1) move glass to vent position. (2) remove mechanism covers and glass panel. (3) remove screws holding drain channel to sup- port frame. Installation (1) reverse preceding operation. Drive cable locators removal (1) position glass 19 mm (0.75 in.) until rearward cable locator ...

  • Page 2147

    Sunshade removal (1) remove wind deflector, mechanism covers and glass panel. (2) position system to full rearward position. (3) slide sunshade panel full forward and release the front tabs from track assembly. (4) pull front and rear retaining clips inboard and lift sunshade out (fig. 8). Installat...

  • Page 2148

    Adjustments glass panel vertical height adjustment (1) open glass to vent position. (2) slide upper half of mechanism covers rearward until clips disengage and separate covers from vehi- cle (fig. 12). (3) close glass panel. Separately loosen adjusting bolts shown in view a (fig. 12) and individuall...

  • Page 2149

    Seats index page page removal and installation bucket seat back cover . . . . . . . . . . . . . 13 bucket seat back . . . . . . . . . . . . . . . . . . . . 13 bucket seat cushion cover . . . . . . . . . . 14 bucket seat track . . . . . . . . . . . . . . . . . . . 14 lumbar support . . . . . . . . . ...

  • Page 2150

    (2) install recliner. Tighten to 28 n·m (20 ft. Lbs.) torque. (3) slide on duon cover. (4) slide on seat back foam cushion (5) install hog rings at seat back base. (6) install seat back cover. (7) route lumbar and heater harness, if equipped. Bucket seat cushion cover removal (1) remove seat from ve...

  • Page 2151

    (3) disengage seat memory module connector, if equipped. (4) separate seat track from seat cushion frame. Installation (1) transfer seat memory module, if equipped. (2) position seat track on seat cushion frame. (3) engage seat memory module connector, if equipped. (4) install nuts attaching seat tr...

  • Page 2152

    Body components index page page diagnosis and testing universal transmitter . . . . . . . . . . . . . . 18 water leaks . . . . . . . . . . . . . . . . . . . . . . . . 17 wind noise . . . . . . . . . . . . . . . . . . . . . . . . . . 18 service procedures body lubrication . . . . . . . . . . . . . . ...

  • Page 2153

    Diagnosis and testing water leaks water leaks can be caused by poor sealing, improper body component alignment, body seam porosity, missing plugs, or blocked drain holes. Cen- trifugal and gravitational force can cause water to drip from a location away from the actual leak point, making leak detect...

  • Page 2154

    Wind noise wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body compo- nent alignment, body seam porosity, or missing plugs in the engine compartment or door hinge pillar areas. All body sealing points should be airtight in normal driving conditions. Mov...

  • Page 2155

    • remove the key. Wipe the lubricant from it with a clean cloth to avoid soiling of clothing. Removal and installation grille removal (1) open hood. (2) remove screws attaching grille to grille open- ing reinforcement (fig. 1). (3) separate grille from vehicle. Installation (1) position grille at gr...

  • Page 2156

    Installation (1) position hood on shims and hinges. Finger- tighten hinge nuts. (2) align hinges and shims with installation refer- ence marks. Tighten hinge nuts to 23 n·m (17 ft-lbs) torque. (3) test latch release cable and latches for proper operation. (4) connect underhood lamp connector. (5) in...

  • Page 2157

    Installation (1) insert replacement cable end through hole in dash panel into engine compartment. (2) pull cable forward and seat grommet in dash panel. (3) position cable bracket on cowl side panel and install screws. Tighten screws to 11 n·m (8 ft-lbs) torque. (4) install left cowl side trim panel...

  • Page 2158

    (5) peel paper backing away from stripe exposing adhesive backing of stripe (fig. 8). (6) apply soap solution liberally to adhesive back- ing of stripe. (7) apply soap solution to body panel surface. (8) place stripe into position on body panel. Smooth out wrinkles by pulling lightly on edges of tap...

  • Page 2159

    (3) if equipped, disengage two-way electrochromic mirror connector from wiring harness. (4) remove clips attaching mirror harness to door inner panel. (5) remove mirror flag seal. (6) remove mirror retaining nuts (fig. 9). (7) remove mirror from door. Refer to group 8, electrical for additional info...

  • Page 2160

    Front door trim panel removal (1) remove screw attaching trim panel to inside release handle (fig. 13). (2) remove screw at armrest. (3) remove screw at the upper mirror bezel. (4) remove the screw in the trim panel depression. (5) using trim remover (c-4829 or equivalent), detach trim panel perimet...

  • Page 2161

    (7) separate door from vehicle. Installation (1) if a replacement front door is being installed, coat door interior with anti-corrosion wax. Also, seal door hem flange with sealant. (2) transfer original hardware. If necessary, refer to applicable procedures. (3) position door in body opening. (4) a...

  • Page 2162

    Installation (1) reverse removal procedure. Front door latch removal (1) remove door trim panel and waterdam. (2) remove door latch retaining screws (fig. 19). (3) disconnect all rods from door latch (fig. 20). (4) disconnect wire connector, if equipped. (5) remove door latch from door. Installation...

  • Page 2163

    Installation (1) reverse removal procedure. Front door inner belt seal removal (1) remove door trim panel. (2) using a trim stick, carefully pry rear inner edge of seal upward. (3) grasp seal and pull upward to separate from door flange (fig. 22). Installation (1) position seal on door flange. (2) f...

  • Page 2164

    Installation (1) position weatherstrip at corners using paint dots as alignment points. (2) move upward and around edge of door opening. Seat seal on flange (fig. 25). (3) engage connector plug with each end of weath- erstrip at bottom of door opening. (4) install b-pillar lower trim panel. (5) inst...

  • Page 2165

    (4) install armrest screw. (5) install mirror bezel screw. (6) install screw attaching trim panel to inside release handle. Rear door removal (1) remove door trim panel. (2) disconnect power window regulator, power door lock motor and all other wire harness connectors. (3) slide wire harness out of ...

  • Page 2166

    Installation (1) support door. (2) position door at c-pillar. (3) install bolts attaching hinge to c-pillar. Tighten outer bolts to 40 n·m (360 in. Lbs.) and inner bolts 34 n·m (300 in. Lbs.) torque. Rear door outside handle removal (1) remove door trim panel and waterdam. If nec- essary, refer to r...

  • Page 2167

    Rear door inner belt seal removal (1) remove door trim panel. (2) using a trim stick, carefully pry rear inner edge of seal upward. (3) grasp seal and pull upward to separate from door flange (fig. 34). Installation (1) position seal on door flange. (2) firmly press downward to seat seal on flange. ...

  • Page 2168

    (3) pry window beltline molding from flange. Remove molding from door. (4) remove window weatherstrip seals from door. (5) remove window track nuts and slide track off of window. (6) remove division bar upper attaching screw and belt line screw (fig. 38). (7) tilt stationary glass channel assembly f...

  • Page 2169

    (2) lift upward and remove molding. Installation—front door (1) replace all retaining clips. (2) install molding over top of retaining clips. (3) align molding to door edges. (4) snap molding down over retaining clips. Removal—rear door (1) open rear door. (2) remove acorn nut at rear dogleg (fig. 4...

  • Page 2170

    Installation (1) position scuff plate on sill and snap into place. Upper b-pillar trim panel removal (1) remove the a-pillar trim panel. (2) remove front seat belt turning loop. (3) detach and remove upper b-pillar trim panel. Installation (1) position trim panel on b-pillar. (2) ensure the trip pan...

  • Page 2171

    Lower b-pillar trim panel removal (1) remove the a-pillar trim panel. (2) remove upper b-pillar trim panel. (3) remove screws attaching lower b-pillar trim panel to b-pillar (fig. 44). (4) remove screws attaching cowl trim panel. (5) separate lower b-pillar trim panel from b-pil- lar. (6) route seat...

  • Page 2172

    Front shoulder belt/buckle removal—buckle (1) slide front seats all the way forward for access to buckle anchor bolt. (2) remove anchor bolt cover. (3) remove buckle anchor bolt. (4) remove shoulder belt buckle from transmission tunnel. Installation—buckle (1) position seat belt buckle in position a...

  • Page 2173

    Removal—shoulder belt (1) unsnap turning loop cover. (2) remove turning loop anchor bolt (fig. 48). (3) remove c-pillar and quarter trim panel. (4) remove belt retractor anchor bolt from rear quarter rail. (5) remove retractor and shoulder belt from panel. Installation—shoulder belt (1) position ret...

  • Page 2174

    Rear seatback removal (1) remove lower seat cushion. Refer to removal procedure. (2) remove bolts holding seatback side support brackets (left side) (fig. 51). (3) tilt seatback forward, and slide it outboard to detach it from pin on center pivot bracket. (4) remove left side (60%) seatback from veh...

  • Page 2175

    (3) if equipped, connect mirror harness wire con- nector. Rearview mirror support bracket installation (1) mark the position for the mirror bracket on the outside of the windshield glass with a wax pencil. (2) clean the bracket contact area on the glass. Use a mild powdered cleanser on a cloth satur...

  • Page 2176

    • press and hold the bracket in place for at least one minute. Note: verify that the mirror support bracket is cor- rectly aligned, because the adhesive will cure rap- idly. (7) allow the adhesive to cure for 8-10 minutes. Remove any excess adhesive with an alcohol-damp- ened cloth. (8) allow the ad...

  • Page 2177

    (6) install assist handles. (7) install a, b, c and d-pillar trim panels. (8) install liftgate opening upper trim panel. (9) if equipped, install sound bar. Liftgate trim panel note: when removing both trim panels from liftgate, remove lower trim panel first. When installing both trim panels, instal...

  • Page 2178

    Liftgate hinge removal it is not necessary to remove liftgate to replace one or both hinges. The hinges can be replaced one at a time. (1) remove liftgate opening (headliner) upper trim molding. (2) disconnect wiring harness to cargo lamp. (3) remove hinge screws at roof panel (fig. 63). (4) remove ...

  • Page 2179

    Liftgate latch striker removal (1) raise liftgate. (2) remove latch striker nuts from below scuff plate. Access nuts from under bumper fascia/beam (fig. 66). (3) remove striker, shim and seal plate. Installation (1) position striker, shim and seal plate on vehicle. (2) install latch striker nuts. Ti...

  • Page 2180

    Flip-up glass switch removal (1) remove liftgate trim panel. (2) remove license plate lamp housing nuts from liftgate. (3) squeeze switch locking tabs inward to release switch from license plate lamp housing. (4) disconnect switch harness connector. (5) separate switch from housing (fig. 69). Instal...

  • Page 2181

    (3) remove latch nuts (fig. 71). (4) disconnect switch connectors. (5) remove latch from liftgate. Installation (1) position latch on vehicle, 2.5 mm forward of seal. (2) connect switch connectors. (3) install latch nuts. Tighten to 11 n·m (100 in. Lbs.). (4) close flip-up glass panel and verify pro...

  • Page 2182

    Luggage rack removal (1) remove slide rail screws (fig. 74). (2) remove luggage rack from vehicle roof. Note: the skid strips are attached to roof panel with adhesive. (3) loosen each skid strip with a heat gun. (4) lift one edge of each skid strip with a putty knife and peel it from roof panel. App...

  • Page 2183

    (4) position the riser covers on the risers and press into place. Adjustments hood adjustment the hood attaching holes are enlarged to aid front, back and side-to-side adjustment. (1) if hood is low in relation to cowl panel, insert shims between hinge and hood. (2) adjust hood bumper (fig. 78) in o...

  • Page 2184

    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 und...

  • Page 2185

    Heating and air conditioning contents page page general information heater and air conditioner controls . 2 heater and air conditioner . . . . . . . . . . . 2 service warnings and precautions . . . . 3 description and operation accumulator . . . . . . . . . . . . . . . . . . . . . . . . 5 ambient te...

  • Page 2186

    General information heater and air conditioner a manual temperature control type heating-air conditioning system is standard factory-installed equipment on this model. An electronically controlled automatic temperature control (atc) type heating- air conditioning system is an available factory-in- s...

  • Page 2187

    Both the manual heater-a/c control panel and the atc control panel and controller units cannot be repaired. If faulty or damaged, the entire unit must be replaced. Service warnings and precautions warning: • the air conditioning system contains refrigerant under high pressure. Severe personal injury...

  • Page 2188

    • do not remove the sealing caps from a replace- ment component until it is to be installed. • when installing a refrigerant line, avoid sharp bends that may restrict refrigerant flow. Position the refrigerant lines away from exhaust system compo- nents or any sharp edges, which may damage the line....

  • Page 2189

    When it is necessary to open the refrigerant sys- tem, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moi...

  • Page 2190

    The same location used for the blower motor resistor on manual temperature control systems. It can be accessed without removing any other components. The power module output to the blower motor can be controlled manually by using the blower motor switch knob on the atc heater-a/c control panel, or a...

  • Page 2191

    The compressor clutch and coil are the only serviced parts on the compressor. Diesel engine the compressor clutch assembly consists of a sta- tionery electromagnetic coil, a hub bearing and rotor assembly, and a clutch plate (fig. 5). The electromag- netic coil and rotor are retained on the compress...

  • Page 2192

    Ant. O-rings on the tube body prevent the refrigerant from bypassing the fixed orifice. The fixed orifice tube is used to meter the flow of liquid refrigerant into the evaporator coil. The fixed orifice tube cannot be repaired and, if faulty or plugged, the liquid line unit must be replaced. Heater ...

  • Page 2193

    Series with the high pressure cut-off switch, between ground and the powertrain control module (pcm). The switch contacts open and close causing the pcm to turn the compressor clutch on and off. This regulates the system pressure and controls evapora- tor temperature. Controlling evaporator temperat...

  • Page 2194

    High pressure gauge hose the high pressure hose (red with black stripe) attaches to the discharge service port. This port is located on the discharge line between the compressor and the condenser, near the front of the engine com- partment. Recovery/recycling/evacuation/charging hose the center mani...

  • Page 2195

    Tor. As the passenger compartment air dehumidifies, the air conditioning system performance levels improve. Humidity has an important bearing on the tempera- ture of the air delivered to the interior of the vehicle. It is important to understand the effect that humidity has on the performance of the...

  • Page 2196

    Wire between the two cavities of the low pressure cycling clutch switch wire harness connector. (7) with the compressor clutch engaged, record the discharge air temperature and the compressor dis- charge pressure. (8) compare the discharge air temperature to the performance temperature and pressure ...

  • Page 2197

    Pressure diagnosis temperature in test area 21–38°c (170–100°f) 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 doe...

  • Page 2198

    Heater performance preparations review the service warnings and precautions in the front of this group before performing the follow- ing procedures. Check the radiator coolant level, serpentine drive belt tension, and engine vacuum line connections. Also check the radiator air flow and the radiator ...

  • Page 2199

    Exact 27 kpa (8 in. Hg.) setting. Otherwise, a false reading will be obtained during testing. Vacuum check valve (1) remove the vacuum check valve. The valve is located in the (black) vacuum supply hose near the engine intake manifold. (2) connect the test set vacuum supply hose to the heater side o...

  • Page 2200

    Atc system the automatic temperature control (atc) control- ler has a system self-diagnostic mode. The controller is capable of troubleshooting each of its input and output circuits. When the controller detects a fault and places it in memory, an “er” is momentarily dis- played in the heater-a/c con...

  • Page 2201

    Value will be a range of numbers between 200 and 255 (fig. 16). (6) t any time during the self-diagnostic tests, you may return to the select test mode by turning the tem- perature rotary control one click in either direction. Again, the stick man and arrows are not shown in the select test mode. At...

  • Page 2202

    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 circ...

  • Page 2203

    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...

  • Page 2204

    Clearing fault codes current faults are cleared whenever the problem goes away. To clear a historical fault, depress and hold either the a/c or recirc button for at least three seconds. The faults have been cleared when two hor- izontal bars appear in the display. Input circuit tests in the input ci...

  • Page 2205

    Test no. Test item test type system tested displayed values 01 blower control switch (a/d) i blower system 9 ?” 9 oc” 9 sc” 00-255 02 blower feedback i blower system 9 ?” 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 do...

  • Page 2206

    Test no. Test item test type system tested displayed values 18 in-vehicle temperature i temperature inputs 9 oc” 9 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 9 oc” 9 sc” 00-255 21 engine coolant i ccd 9 ?” -40 to ...

  • Page 2207

    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 ...

  • Page 2208

    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 (cp...

  • Page 2209

    Blower motor for circuit descriptions and diagrams, refer to 8w-42 - air conditioning/heater in group 8w - wir- ing diagrams. Possible causes of an inoperative blower motor include: • faulty fuse • faulty blower motor ground circuit wire har- nesses or connectors • faulty blower motor resistor (manu...

  • Page 2210

    (3) tighten all compressor mounting bolts, the clutch mounting nut, the clutch coil mounting screw or nut, and the serpentine drive belt to the correct specifications. (4) check the refrigerant system plumbing for rub- bing or interference, which can cause unusual noises. (5) check the refrigerant s...

  • Page 2211

    Be continuity between this cavity and the a/c com- pressor clutch relay output circuit cavity of the com- pressor clutch coil wire harness connector. If ok, go to step 4. If not ok, repair the open circuit as required. (4) the relay coil battery terminal (86) is con- nected to the fused ignition swi...

  • Page 2212

    Grams, refer to 8w-42 - air conditioning/heater in group 8w - wiring diagrams. (1) unplug the low pressure cycling clutch switch wire harness connector from the switch on the accu- mulator, and install a jumper wire between the two connector cavities. (2) connect a manifold gauge set to the refriger...

  • Page 2213

    Vacuum pump. Then open the suction and discharge valves and evacuate an additional ten minutes. (3) close all of the valves. Turn off and disconnect the vacuum pump. (4) the refrigerant system is now ready to be charged with refrigerant. Refrigerant system charge warning: review the warnings and cau...

  • Page 2214

    12° c (54° f) and the evaporator outlet tube temper- ature is 10° c (50° f). Subtract the inlet tube tem- perature from the outlet tube temperature. The difference is -2° c (-4° f). With a -2° c (-4° f) tem- perature differential at 21° c (70° f) ambient tem- perature, the system is fully charged. (...

  • Page 2215

    Removal and installation refrigerant line coupler warning: review the warnings and cau- tions in the front of this group before performing the following operation. Removal (1) recover the refrigerant from the refrigerant system as described in this group. (2) remove the secondary clip from the coupl...

  • Page 2216

    (3) unplug the compressor clutch coil wire harness connector. (4) recover the refrigerant from the refrigerant system as described in this group. (5) remove the refrigerant lines from the compres- sor. Install plugs in, or tape over all of the open refrigerant fittings. (6) remove the bolts that sec...

  • Page 2217

    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 pulley retaining snap ring with snap ring pliers (special tool c-4574) and slide the pulley assembly off of the compressor (fig. 23). (5) unplug th...

  • Page 2218

    (2) install the clutch coil wire harness retaining clip on the compressor front housing and tighten the retaining screw. Plug in the clutch coil wire harness connector. (3) install the clutch field coil and snap ring with snap ring pliers (special tool c-4574). The bevel side of the snap ring must b...

  • Page 2219

    (4) insert the two pins of the spanner wrench into two holes of the clutch plate. Hold the clutch plate stationary and remove the bolt that secures the clutch plate to the compressor shaft. (5) remove the clutch plate (fig. 27). (6) remove the external snap ring from the front compressor housing hub...

  • Page 2220

    Subtract shims as required. The specification is 0.41 to 0.79 mm (0.016 to 0.031 inch). If the air gap is not consistent around the circumference, lightly pry up at the points of minimum variation. Lightly tap down at the points of maximum variation. (6) install the drive plate onto the clutch and t...

  • Page 2221

    High pressure relief valve warning: review the warnings and cau- tions in the front of this group before performing the following operation. Removal (1) disconnect and isolate the battery negative cable. (2) recover the refrigerant from the refrigerant system as described in this group. (3) turn the...

  • Page 2222

    (8) install the grille panel. (9) remove the plugs or tape from the open refrig- erant line fittings and connect the refrigerant lines to the condenser. (10) evacuate the refrigerant system as described in this group. (11) charge the refrigerant system as described in this group. (12) connect the ba...

  • Page 2223

    Fixed orifice tube the fixed orifice tube is located in the liquid line near the condenser. The orifice has filter screens on the inlet and outlet ends of the tube body. If the fixed orifice tube is faulty or plugged, the liquid line must be replaced. Warning: review the warnings and cau- tions in t...

  • Page 2224

    Vacuum check valve (1) unplug the vacuum supply line at the intake manifold. (2) note the orientation of the check valve in the vacuum line for correct installation. (3) unplug the valve from the vacuum supply line fittings. (4) reverse the removal procedures to install. Vacuum reservoir (1) remove ...

  • Page 2225

    (6) remove the heater-a/c control from the instru- ment panel. Installation (1) connect the vacuum and wire harness connec- tors to the heater-a/c control. (2) install the heater-a/c control to the instrument panel and secure with three screws. (3) install the inboard switch pod bezel. (4) connect t...

  • Page 2226

    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 ...

  • Page 2227

    (6) plug the wire harness connector into the blower motor and install the wire harness into the retainer. (7) connect the blower motor cooling tube. (8) connect the battery negative cable. Blower motor resistor and power module removal (1) disconnect and isolate the battery negative cable. (2) unplu...

  • Page 2228

    (3) unclip the blower motor relay wire harness connector from the side of the heater-a/c housing. (4) unplug the blower motor relay from the con- nector. Installation (1) align the blower motor relay terminals with the cavities in the blower motor relay wire harness connector. (2) push the relay fir...

  • Page 2229

    (5) remove the nut that secures the floor duct to the stud on the floor pan transmission tunnel (fig. 51). (6) disconnect the floor duct from the center adap- tor duct. (7) remove the floor duct from the vehicle. (8) reverse the removal procedures to install. Demister outlets (1) using a trim stick ...

  • Page 2230

    Installation (1) install the panel/defrost door through the top opening and place into position in the heater-a/c housing. (2) press the door pivot shaft retainer onto the pivot shaft. (3) connect the actuating rod and rod clip to the shaft retainer. (4) install the instrument panel as described in ...

  • Page 2231

    (11) unplug the heater-a/c housing wire harness connectors. (12) remove the heater-a/c housing mounting nuts from the studs on the passenger compartment side of the dash panel (fig. 58). (13) remove the heater-a/c housing from the vehi- cle. Installation (1) position the heater-a/c housing to the da...

  • Page 2232

    (2) position the retainer clips over the heater core tubes. Install and tighten the screws that secure the heater core in the heater-a/c housing. (3) install the heater-a/c housing as described in this group. Evaporator coil removal (1) remove the heater-a/c housing as described in this group. (2) t...

  • Page 2233

    (3) press the door pivot connection onto the door pivot pin. (4) plug in the vacuum harness connector to the actuator. (5) install the heater-a/c housing as described in this group. Panel/defrost door actuator this actuator is used only on models equipped with the standard manual temperature control...

  • Page 2234

    Center heat duct adaptor to access and remove the final screw. (6) remove the bottom half of the heater-a/c hous- ing. (7) remove the heat/defrost door. Installation (1) position the door pivot pin in the pivot hole. (2) press the actuator door pivot connection onto the door pivot pin. (3) position ...

  • Page 2235: Emission Control Systems

    Emission control systems contents page page evaporative emission controls . . . . . . . 13 on-board diagnostics . . . . . . . . . . . . . . . . . 1 on-board diagnostics index page page general information system description . . . . . . . . . . . . . . . . . . 1 description and operation circuit actu...

  • Page 2236

    Detected, the pcm sends a message to the instru- ment cluster to illuminate the lamp. The pcm illu- minates the mil only for dtc’s that affect vehicle emissions. There are some monitors that may take two consecutive trips, with a detected fault, before the mil is illuminated. The mil stays on contin...

  • Page 2237

    The passenger compartment; at the lower edge of instrument panel; near the steering column. (2) turn the ignition switch on and access the “read fault” screen. (3) record all the dtc’s and “freeze frame” infor- mation shown on the drb scan tool. (4) to erase dtc’s, use the “erase trouble code” data ...

  • Page 2238

    Hex code mil code generic scan tool code drb scan tool display description of diagnostic trouble code 0f 34* speed control solenoid circuits an open or shorted condition detected in the speed control vacuum or vent solenoid circuits. 10 33* a/c clutch relay circuit an open or shorted condition detec...

  • Page 2239

    Hex code mil code generic scan tool code drb scan tool display description of diagnostic trouble code 31 63** p1696 pcm failure eeprom write denied unsuccessful attempt to write to an eeprom location by the pcm. 32 37** p0753 trans 3-4 shift sol/trans relay circuits current state of output port for ...

  • Page 2240

    Hex code mil code generic scan tool code drb scan tool display description of diagnostic trouble code 69 p0141 downstream,left bank downstream or pre-catalyst heater failure oxygen sensor heating element circuit malfunction. 6a 43** p0300 multiple cylinder mis-fire misfire detected in multiple cylin...

  • Page 2241

    Hex code mil code generic scan tool code drb scan tool display description of diagnostic trouble code 94 37* p0740 torq conv clu, no rpm drop at lockup relationship between engine speed and vehicle speed indicates no torque converter clutch engagement (auto. Trans. Only). 95 42* fuel level sending u...

  • Page 2242

    Hex code mil code generic scan tool code drb scan tool display description of diagnostic trouble code a9 p1762 governor press sen offset volts too lo or high sensor input greater or less than calibration for 3 consecutive neutral/park occurances. Ab 37** p0748 governor pressure sol control/trans rel...

  • Page 2243

    Monitored systems there are new electronic circuit monitors that check fuel, emission, engine and ignition perfor- mance. These monitors use information from various sensor circuits to indicate the overall operation of the fuel, engine, ignition and emission systems and thus the emissions performanc...

  • Page 2244

    Pump by drawing air into the pump cavity and also closes the vent seal. During non test conditions the vent seal is held open by the pump diaphragm assembly which pushes it open at the full travel posi- tion. The vent seal will remain closed while the pump is cycling due to the reed switch triggerin...

  • Page 2245

    Verter. The pcm calculates the a/f mixture from the output of the o2s. A low voltage indicates high oxy- gen content (lean mixture). A high voltage indicates a low content of oxygen (rich mixture). When the upstream o2s detects a lean condition, there is an abundance of oxygen in the exhaust gas. A ...

  • Page 2246

    Pcm to store diagnostic trouble codes for other sys- tems or components. For example, a fuel pressure problem will not register a fault directly, but could cause a rich/lean condition or misfire. This could cause the pcm to store an oxygen sensor or misfire diagnostic trouble code fuel pressure the ...

  • Page 2247

    Evaporative emission controls index page page description and operation crankcase breather/filter—5.2l/5.9l engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 crankcase ventilation (ccv) system— 4.0l engine . . . . . . . . . . . . . . . . . . . . . . . . . 16 duty cycle evap canister ...

  • Page 2248

    Fuel tank pressure vents into the evap canister. Fuel vapors are temporarily held in the canister until they can be drawn into the intake manifold. The duty cycle evap canister purge solenoid allows the evap canister to be purged at predetermined times and at certain engine operating conditions. For...

  • Page 2249

    Pump mode: the pump is cycled at a fixed rate to achieve a rapid pressure build in order to shorten the overall test time. Test mode: the solenoid is energized with a fixed duration pulse. Subsequent fixed pulses occur when the diaphragm reaches the switch closure point. The spring in the pump is se...

  • Page 2250

    A closed engine crankcase breather/filter, with a hose connecting it to the air cleaner housing, pro- vides the source of air for system. The pcv system operates by engine intake mani- fold vacuum (fig. 6). Filtered air is routed into the crankcase through the air cleaner hose and crank- case breath...

  • Page 2251

    Extensively on short run, stop and go or extended engine idle service, or extreme dust conditions. Vehicle emission control information (veci) label all vehicles are equipped with a combined veci label. This label is located in the engine compart- ment (fig. 12) and contains the following: • engine ...

  • Page 2252

    Breather/filter at the cylinder head (valve) cover (fig. 14). (3) the paper should be drawn against the opening in the cylinder head (valve) cover with noticeable force. This will be after allowing approximately one minute for crankcase pressure to reduce. (4) turn engine off and remove pcv valve fr...

  • Page 2253

    Installation (1) position canister to body. (2) install canister mounting nuts. Tighten nuts to 9 n·m (80 in. Lbs.) torque. (3) connect vacuum lines. Be sure vacuum lines are firmly connected and not leaking or damaged. If leaking, a diagnostic trouble code (dtc) may be set with certain emission pac...

  • Page 2254

    Leaks. If a leak is present, a diagnostic trouble code (dtc) may be set. Specifications torque chart description torque evap canister mounting nuts . . 9 n·m (80 in. Lbs.) evap canister purge solenoid mounting nuts . . . . . . . . . . . . 5 n·m (45 in. Lbs.) ldp pump bracket nuts . . . . . . . 7 n·m...

  • Page 2255: Emission Control System

    Emission control system contents page page exhaust emission controls—2.5l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 on-board diagnostics—2.5l diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 on-board diagnostics—2.5l diesel engine index pa...

  • Page 2256

    Vacuum assist: leaks or restrictions in the vac- uum circuits of vacuum assisted engine control sys- tem devices are not monitored by the msa. Msa system ground: the msa cannot deter- mine a poor system ground. However, a dtc may be generated as a result of this condition. Msa/pcm connector engageme...

  • Page 2257

    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 coo...

  • Page 2258

    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 st...

  • Page 2259

    Exhaust emission controls—2.5l diesel engine index page page description and operation exhaust gas recirculation (egr) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 vacuum hose routing schematic . . . . . . 5 diagnosis and testing egr gas flow test . . . . . . . . . . . . . . . ...

  • Page 2260

    • the vacuum pump supplies vacuum for the evm and the egr valve. This pump also supplies vacuum for operation of the power brake booster. The pump is located internally in the front of the engine block (fig. 3) and is driven by the crankshaft gear. • vacuum lines and hoses to connect the various com...

  • Page 2261

    Removal and installation egr valve removal (1) remove the rubber hose from turbocharger to metal tube. (2) disconnect vacuum line at egr valve vacuum supply fitting (fig. 2). (3) loosen the tube fitting at exhaust manifold end of egr tube (fig. 2). (4) remove the two bolts retaining the egr tube to ...

  • Page 2262

    Specifications torque chart—2.5l diesel description torque egr valve mounting bolts . . . 23 n·m (204 in. Lbs.) egr tube mounting bolts . . . . 23 n·m (204 in. Lbs.) evm (electric vacuum modulator) mounting bolt . . . . . . . . . . . . . 2 n·m (20 in. Lbs.) 25 - 8 emission control system zg.